Page 1

FS / FST SERVICE MANUAL SERVICE MANUAL FOREWORD This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as specified. Comments or suggestions about this manual may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 HWY 55 Medina, Minnesota 55340.

FS / FST Service Manual PN 9921066 Š Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.


UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols:

WARNING

SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle.

CAUTION

SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION

CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage. NOTE: NOTE provides key information by clarifying instructions. IMPORTANT: IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Rapid Reaction Clutch, Registered Trademark of Team Industries, Inc. Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.


Model Specifications

CHAPTER 1 Model Specifications

1

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 2006 FS CLASSIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 2006 FST CLASSIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 2006 FS TOURING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 2006 FST TOURING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 2006 FST SWITCHBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 2007 FST IQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 2007 FST IQ LX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 2007 FS IQ TOURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 2007 FST IQ TOURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18 2007 FST IQ CRUISER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 2007 FST IQ SWITCHBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22 2008 IQ TURBO DRAGON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24 2008 IQ TURBO LX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26 2008 TURBO SWITCHBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28 2008 FS IQ TOURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30 2008 FST IQ TOURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32 2008 IQ CRUISER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34

FS / FST Service Manual 9921066

1.1


Model Specifications SPECIFICATIONS

Table 1-2: General

2006 FS Classic Model Number: S06PD7ES Engine 8 Valve - SOHC - Parallel Twin Cylinder w/ Counter Balancer

Engine Type Displacement

48 / 121.9

Length (in/cm)

115 / 292.1

Height (in/cm)

53 / 134.6

Estimated Dry Weight (lb/kg)

591 / 268

Fuel (Gallons / Liters)

9.2 / 34.8

Oil qts/l

3/2.8

749cc

Bore (inches/mm)

3.45 / 85

Stroke (inches/mm)

2.60 / 66

Engine Oil - PS4 Plus Equivalent = 0W-50 Synthetic SL Minimum Rating

Piston to Cylinder Clearance (inches/mm)

0.0006-0.002 / 0.017-0.052

Ring Installed End-Gap Top Ring Middle Ring Oil Control Ring (inches / mm)

0.009-0.019 / 0.25-0.50 0.007 - 0.013 / 0.20 - 0.35 0.005 - 0.011 / 0.15 - 0.30

Operating RPM ±200

8000

Idle RPM

1450

Engagement RPM ±200

3500

DRIVE CLUTCH Shift Weight

0-600 (0-2000)

11-50

600-1200 (2000-4000)

11-48

1200-1800 (4000-6000)

11-44

1800-2400 (6000-8000)

11-42

2400-3000 (8000-10,000)

11-40

3000-3600 (10,000-12,000)

11-40

Clutch Spring

DRIVEN CLUTCH Clutch Spring

Driven Helix

Gearing

Red/Black

62/40.46 64/40.55 NON-ER

21:46-80

3120 60/340

3076 40/340

Drive Clutch Bolt Torque: 50 lb.ft. (68Nm)

0451848

Oil Breather Foam

5813009

Coolant qts/l

6.34/6.0

Brake Fluid

DOT 4

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

3211099 1.49 / 3.78 28_ 46.063 / 116.9 11 / 28 8.42 21 46 80 Polaris Synthetic 9 / 266.2 Perc 4

Table 1-3: Fuel Delivery Type Throttle Body Marking

Sequential Fuel Injection 1253520-01

Throttle Body Bore

46mm

TPS Voltage @ Idle

0.56 Vdc

Fuel Pressure - PSI (bar)

43.5 (3.0)

Recommended Fuel Octane (R+M/2)

1.2

2876244 (Quart) 2875522 (Oil Kit) Kit includes 3 quarts oil, filter, o-ring, and ignition jumper.

Oil Filter (paper cartridge)

Drive Belt Part Number Width (inches / cm) Side Angle Circumference (inches / cm) Center Distance (inches / cm)

Table 1-1: Clutching ALTITUDE meters (feet)

Width (in/cm)

FS / FST Service Manual 9921066

87 (Minimum)


Model Specifications Table 1-4: Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total) Watts @ 13.5 Vdc (After EMS) Amps @ 13.5 Vdc (No Load)

Table 1-7: Rear Suspension Suspension Type

13.5 - 14.5 Vdc 780 630 60

Ignition Timing

Variable

Spark Plug Gap in.(mm)

.030 (.75)

Spark Plug OE

Champion RC7YC 3070195 Champion RC7PYCBX 3021837

Equivalent

Table 1-5: Track Width - Inches (cm)

15 (38)

Length - Inches (cm)

128 (325)

Lug Height - Inches (cm) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

1.25 (3.175)

Front Track Shock (FTS)

1

Fast M-10 128 Fox HPG w/IFP (Rebuildable)

FTS Spring Rate lbs/in (N/mm)

180 (31)

FTS Spring Installed Length Inches (cm)

8.5 (21.6)

Rear Track Shock (RTS)

Fox HPG w/IFP (Rebuildable)

Lower Outer Spring Rate lbs/in (N/mm)

715 (125)

Lower Inner Spring Rate lbs/in (N/mm)

425 (74.4)

Upper Spring Rate lbs/in (N/mm)

273 (48)

Rear Travel Inches (cm)

13 (33)

7/8″- 1 1/8″ (2.2 - 2.9cm)

Table 1-6: Front Suspension Suspension Type Shocks IFS Spring Rate lbs/in (N/mm)

IQ Nitrex Select 120 (21)

Spring Installed Length Inches (cm)

9.95 (25.3)

Front Vertical Travel Inches (cm)

9.92 (25.2)

Ski Center Distance Inches (cm)

42.5 (108)

Camber Inches (cm)

2.25 ± 0.31 (57.2 ± 0.79)

Toe Out Inches (cm)

0 - 0.12 (0 - 0.31)

FS / FST Service Manual 9921066

1.3


Model Specifications 2006 FST Classic

Table 1-10: General

Model Numbers: S06PD7FS / S07PD7FE Table 1-8: Engine Engine Type

8 Valve - SOHC - Parallel Twin Cylinder w/ Counter Balancer

Displacement

749cc

Bore (inches/mm)

3.45 / 85

Stroke (inches/mm)

2.60 / 66

Piston to Cylinder Clearance (inches/mm)

Width (in/cm)

48 / 121.9

Length (in/cm)

115 / 292.1

Height (in/cm)

53 / 134.6

Estimated Dry Weight (lb/kg)

600 / 272

Fuel (Gallons / Liters)

9.2 / 34.8

Engine Oil - PS4 Plus Equivalent = 0W-50 Synthetic SL Minimum Rating

0.0006-0.002 / 0.017-0.052

2876244 (Quart) 2875522 (Kit) Kit includes 3 quarts oil, filter, o-ring, and ignition jumper.

Oil qts/l

Ring Installed End-Gap Top Ring Middle Ring Oil Control Ring (inches / mm)

0.009-0.019 / 0.25-0.50 0.007 - 0.013 / 0.20 - 0.35 0.005 - 0.011 / 0.15 - 0.30

3 / 2.8

Oil Filter (paper cartridge)

0451848

Coolant qts/l

6.34 / 6.0

Brake Fluid

DOT 4

Operating RPM ±200

8000

Air Filter

5812801

Idle RPM

1550

Oil Breather Foam

5812950

Engagement RPM ±200

3800

Drive Belt Part Number Width (inches / cm) Side Angle Ride Out Circumference (inches / cm) Center Distance (inches / cm)

Table 1-9: Clutching ALTITUDE meters (feet)

DRIVE CLUTCH Shift Weight

Clutch Spring

DRIVEN CLUTCH Clutch Spring

Driven Helix

Gearing

0-600 (0-2000) 600-1200 (2000-4000)

3121 100/340

24:40-78

11-66 1200-1800 (4000-6000)

Red/ Black

1800-2400 (6000-8000) 2400-3000 (8000-10,000)

64/38-.65 (64/38-.46) NON ER

Black/ Green

23:46-80

11-64CS

Chaincase Center Distance (in) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

3000-3600 (10,000-12,000)

3211121 1.46 / 3.71 26_ .09 / 2.3mm 45.79 / 116.3 11 / 28 8.42 24 40 78 Polaris Synthetic 9 / 266.2 Perc 4

Table 1-11: Fuel Delivery

Drive Clutch Bolt Torque: 50 Ft. Lbs. (68Nm)

Type Throttle Body Marking

1253519-01

Throttle Body Bore

39mm

TPS Voltage @ Idle

0.585 Vdc

Fuel Pressure PSI (bar) + Boost Recommended Fuel Octane (R+M/2)

1.4

Sequential Fuel Injection

FS / FST Service Manual 9921066

43.5 (3.0) + Boost 87 (Reduced Performance) 91,92,93 (Recomended)


Model Specifications Table 1-12: Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total) Watts @ 13.5 Vdc (After EMS) Amps @ 13.5 Vdc (No Load)

Table 1-15: Rear Suspension Suspension Type

13.5 - 14.5 Vdc 780 630 60

Ignition Timing

Variable

Spark Plug Gap in.(mm)

.030 (.75)

Spark Plug OE

Champion RC7PYC 04513967 Champion RC7PYCBX 3021837

Equivalent

Table 1-13: Track Width in (cm)

15 (38)

Length in (cm)

144 (366)

Lug Height in (cm) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

1.25 (3.175)

Front Track Shock (FTS)

1

Fast M-10 128 Fox HPG w/IFP (Rebuildable)

FTS Spring Rate lbs/in (N/mm)

180 (31)

FTS Spring Installed Length Inches (cm)

8.5 (21.6)

Rear Track Shock (RTS)

Fox HPG w/IFP (Rebuildable)

Lower Outer Spring Rate lbs/in (N/mm)

715 (125)

Lower Inner Srping Rate lbs/in (N/mm)

425 (74.4)

Upper Spring Rate lbs/in (N/mm)

273 (48)

Rear Travel Inches (cm)

13 (33)

7/8″- 1 1/8″ (2.2 - 2.9cm)

Table 1-14: Front Suspension Suspension Type Shocks IFS Spring Rate lbs/in (N/mm)

IQ Nitrex Select 120 (21)

Spring Installed Length Inches (cm)

9.95 (25.3)

Front Vertical Travel Inches (cm)

9.92 (25.2)

Ski Center Distance Inches (cm)

42.5 (108)

Camber Inches (cm)

2.25 ± 0.31 (57.2 ± 0.79)

Toe Out Inches (cm)

0 - 0.12 (0 - 0.31)

FS / FST Service Manual 9921066

1.5


Model Specifications 2006 FS Touring

Table 1-18: General

Model Number: S06PT7ES Table 1-16: Engine Engine Type

8 Valve - SOHC - Parallel Twin Cylinder w/ Counter Balancer

Displacement

749cc

Bore (inches/mm)

3.45 / 85

Stroke (inches/mm)

2.60 / 66

Piston to Cylinder Clearance (inches/mm) Ring Installed End-Gap Top Ring Middle Ring Oil Control Ring (inches / mm)

Width (in/cm)

48 / 121.9

Length (in/cm)

115 / 292.1

Height (in/cm)

48 / 121.9

Estimated Dry Weight (lb/kg)

640 / 290

Fuel (Gallons / Liters)

9.2 / 34.8

Engine Oil - PS4 Plus Equivalent = 0W-50 Synthetic SL Minimum Rating

0.0006-0.002 / 0.017-0.052

0.009-0.019 / 0.25-0.50 0.007 - 0.013 / 0.20 - 0.35 0.005 - 0.011 / 0.15 - 0.30

Oil qts/l

3 / 2.8

Coolant qts/l

7 / 6.6

Brake Fluid

DOT 4

Oil Filter (paper cartridge)

0451848 5813009

Operating RPM ±200

8000

Oil Breather Foam

Idle RPM

1450

Engagement RPM ±200

3500

Drive Belt Part Number Width (inches / cm) Side Angle Circumference (inches / cm) Center Distance (inches / cm)

Table 1-17: Clutching ALTITUDE meters (feet)

DRIVE CLUTCH Shift Weight

0-600 (0-2000)

11-52

600-1200 (2000-4000)

11-50

1200-1800 (4000-6000)

11-46

1800-2400 (6000-8000)

11-44

2400-3000 (8000-10,000)

11-42

3000-3600 (10,000-12,000)

11-40

Clutch Spring

DRIVEN CLUTCH Clutch Spring

Driven Helix

Gearing

Red/Black

62/40.46 (64/40.55) NON ER

21:46-80

3121 60/340

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

3076 40/340

Drive Clutch Bolt Torque 50 Ft.Lbs. (68Nm)

3211099 1.49 / 3.78 28_ 46.063 / 116.9 11 / 28 8.42 21 46 80 Polaris Synthetic 9 / 266.2 Perc 4

Table 1-19: Fuel Delivery Type Throttle Body Marking

Sequential Fuel Injection 1253520-01

Throttle Body Bore

46mm

TPS Voltage @ Idle

0.56 Vdc

Fuel Pressure - PSI (bar)

43.5 (3.0)

Recommended Fuel Octane (R+M/2)

1.6

2876244 (Quart) 2875522 (Kit) Kit includes 3 quarts oil, filter, o-ring, and ignition jumper.

FS / FST Service Manual 9921066

87 (Minimum)


Model Specifications Table 1-20: Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total) Watts @ 13.5 Vdc (After EMS) Amps @ 13.5 Vdc (No Load)

Table 1-23: Rear Suspension Suspension Type

13.5 - 14.5 Vdc 780 630 60

Ignition Timing

Variable

Spark Plug Gap in.(mm)

.030 (.75)

Spark Plug OE

Champion RC7YC 3070195 Champion RC7PYCBX 3021837

Equivalent

Table 1-21: Track Width in. (cm)

15 (38)

Length in. (cm)

136 (345)

Lug Height in. (cm) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

Front Track Shock (FTS) FTS Spring Rate lbs/in (N/mm)

1

Fast M-10 136 Fox HPG w/IFP (Rebuildable) 220 (38.5)

Mid Track Shock (MTS)

Nitrex Gas Bag

Rear Track Shock (RTS)

Fox HPG w/IFP (Rebuildable)

Lower Outer Spring Rate lbs/in (N/mm)

715 (125)

Lower Inner Spring Rate lbs/in (N/mm)

425 (74.4)

Upper Spring Rate lbs/in (N/mm)

273 (48)

Rear Travel Inches (cm)

14 (35.6)

1 (2.54) 7/8″- 1 1/8″ (2.2 - 2.9cm)

Table 1-22: Front Suspension Suspension Type Shocks IFS Spring Rate lbs/in (N/mm)

IQ Nitrex Select 120 (21)

Spring Installed Length Inches (cm)

9.95 (25.3)

Front Vertical Travel Inches (cm)

9.92 (25.2)

Ski Center Distance Inches (cm)

42.5 (108)

Camber Inches (cm)

2.25 ± 0.31 (57.2 ± 0.79)

Toe Out Inches (cm)

0 - 0.12 (0 - 0.31)

FS / FST Service Manual 9921066

1.7


Model Specifications 2006 FST Touring

Table 1-26: General

Model Number: S06PT7FS Table 1-24: Engine Engine Type

8 Valve - SOHC - Parallel Twin Cylinder w/ Counter Balancer

Displacement

749cc

Bore (inches/mm)

3.45 / 85

Stroke (inches/mm)

2.60 / 66

Piston to Cylinder Clearance (inches/mm) Ring Installed End-Gap Top Ring Middle Ring Oil Control Ring (inches / mm)

Width (in/cm)

48 / 121.9

Length (in/cm)

115 / 292.1

Height (in/cm)

48 / 121.9

Estimated Dry Weight (lb/kg)

660 / 299

Engine Oil - PS4 Plus Equivalent = 0W-50 Synthetic SL Minimum Rating

0.0006-0.002 / 0.017-0.052

0.009-0.019 / 0.25-0.50 0.007 - 0.013 / 0.20 - 0.35 0.005 - 0.011 / 0.15 - 0.30

2876244 (Quart) 2875522 (Kit) Kit includes 3 quarts oil, filter, o-ring, and ignition jumper.

Fuel (Gallons / Liters)

9.2 / 34.8

Oil qts/l

3 / 2.8

Coolant qts/l

7 / 6.6

Brake Fluid

DOT 4

Oil Filter (paper cartridge)

0451848

Operating RPM ±200

8000

Air Filter

5812801

Idle RPM

1550

Oil Breather Foam

5812950

Engagement RPM ±200

3800

Drive Belt Part Number Width (inches / cm) Side Angle Ride Out Circumference (inches / cm) Center Distance (inches / cm)

Table 1-25: Clutching ALTITUDE meters (feet)

DRIVE CLUTCH Shift Weight

Clutch Spring

DRIVEN CLUTCH Clutch Spring

Driven Helix

Gearing

0-600 (0-2000) 600-1200 (2000-4000)

3121 100/340

24:44-80

11-66 1200-1800 (4000-6000) RED/BLK 1800-2400 (6000-8000) 2400-3000 (8000-10,000)

64/38-.65 NON ER

BLK/GRN 11-64CS

23:46-80

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

3000-3600 (10,000-12,000)

3211121 1.46 / 3.71 26_ .09 / 2.3mm 45.79 / 116.3 11 / 28 8.42 24 44 80 Polaris Synthetic 9 / 266.2 Perc 4

Table 1-27: Fuel Delivery

Drive Clutch Bolt Torque 50 Ft.Lbs. (68Nm)

Type Throttle Body Bore

39mm

TPS Voltage @ Idle

0.585 Vdc

Fuel Pressure (PSI/bar) Recommended Fuel Octane (R+M/2)

1.8

Sequential Fuel Injection

FS / FST Service Manual 9921066

43.5 / 3 + Boost 87 (Reduced Performance) 91,92,93 (Recomended)


Model Specifications Table 1-28: Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total) Watts @ 13.5 Vdc (After EMS) Amps @ 13.5 Vdc (No Load)

Table 1-31: Rear Suspension Suspension Type

13.5 - 14.5 Vdc 780 630 60

Ignition Timing

Variable

Spark Plug Gap in.(mm)

.030 (.75)

Spark Plug OE

Champion RC7PYC 04513967 Champion RC7PYCBX 3021837

Equivalent

Table 1-29: Track Width in. (cm)

15 (38)

Length in. (cm)

136 (345)

Lug Height in. (cm) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

Front Track Shock (FTS) FTS Spring Rate lbs/in (N/mm)

1

Fast M-10 136 Fox HPG w/IFP (Rebuildable) 220 (38.5)

Mid Track Shock (MTS)

Nitrex Gas Bag

Rear Track Shock (RTS)

Fox HPG w/IFP (Rebuildable)

Lower Outer Spring Rate lbs/in (N/mm)

715 (125)

Lower Inner Spring Rate lbs/in (N/mm)

425 (74.4)

Upper Spring Rate lbs/in (N/mm)

273 (48)

Rear Travel Inches (cm)

14 (35.6)

1 (2.54) 7/8″- 1 1/8″ (2.2 - 2.9cm)

Table 1-30: Front Suspension Suspension Type Shocks IFS Spring Rate lbs/in (N/mm)

IQ Nitrex Select 120 (21)

Spring Installed Length Inches (cm)

9.95 (25.3)

Front Vertical Travel Inches (cm)

9.92 (25.2)

Ski Center Distance Inches (cm)

42.5 (108)

Camber Inches (cm)

2.25 ± 0.31 (57.2 ± 0.79)

Toe Out Inches (cm)

0 - 0.12 (0 - 0.31)

FS / FST Service Manual 9921066

1.9


Model Specifications 2006 FST Switchback

Table 1-34: General

Model Numbers: S06PS7FS / S07PS7FE Table 1-32: Engine Engine Type

8 Valve - SOHC - Parallel Twin Cylinder w/ Counter Balancer

Displacement

749cc

Bore (inches/mm)

3.45 / 85

Stroke (inches/mm)

2.60 / 66

Piston to Cylinder Clearance (inches/mm) Ring Installed End-Gap Top Ring Middle Ring Oil Control Ring (inches / mm)

Width (in/cm)

48 / 121.9

Length (in/cm)

128 / 325.1

Height (in/cm)

48.5 / 123.2

Estimated Dry Weight (lb/kg)

600 / 272

Fuel (Gallons / Liters)

9.2 / 34.8

Engine Oil - PS4 Plus Equivalent = 0W-50 Synthetic SL Minimum Rating

0.0006-0.002 / 0.017-0.052

2876244 (Quart) 2875522 (Kit) Kit includes 3 quarts oil, filter, o-ring, and ignition jumper.

Oil qts/l 0.009-0.019 / 0.25-0.50 0.007 - 0.013 / 0.20 - 0.35 0.005 - 0.011 / 0.15 - 0.30

3 / 2.8

Coolant qts/l

6.34 / 6.0

Brake Fluid

DOT 4

Oil Filter (paper cartridge)

0451848

Operating RPM ±200

8000

Air Filter

5812801

Idle RPM

1550

Oil Breather Foam

5812950

Engagement RPM ±200

3800

Drive Belt Part Number Width (inches / cm) Side Angle Ride Out Circumference (inches / cm) Center Distance (inches / cm)

Table 1-33: Clutching ALTITUDE meters (feet)

DRIVE CLUTCH Shift Weight

Clutch Spring

DRIVEN CLUTCH Clutch Spring

Driven Helix

Gearing

0-600 (0-2000) 600-1200 (2000-4000)

3121 100/340

24:40-78

11-66 1200-1800 (4000-6000) RED/BLK 1800-2400 (6000-8000) 2400-3000 (8000-10,000)

64/38-.65 NON ER

BLK/GRN 11-64CS

23:46-80

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

3000-3600 (10,000-12,000)

3211121 1.46 / 3.71 26_ .09 / 2.3mm 45.79 / 116.3 11 / 28 8.42 24 40 78 Polaris Synthetic 9 / 266.2 Perc 4

Table 1-35: Fuel Delivery

Drive Clutch Bolt Torque 50 Ft.Lbs. (68Nm)

Type Throttle Body Marking

1253519-01

Throttle Body Bore

39mm

TPS Voltage @ Idle

0.585 Vdc

Fuel Pressure PSI (bar) + Boost Recommended Fuel Octane (R+M/2)

1.10

Sequential Fuel Injection

FS / FST Service Manual 9921066

43.5 (3.0) + Boost 87 (Reduced Performance) 91,92,93 (Recomended)


Model Specifications Table 1-36: Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total) Watts @ 13.5 Vdc (After EMS) Amps @ 13.5 Vdc (No Load)

Table 1-39: Rear Suspension Suspension Type

13.5 - 14.5 Vdc 780 630 60

Ignition Timing

Variable

Spark Plug Gap in.(mm)

.030 (.75)

Spark Plug OE

Champion RC7PYC 04513967 Champion RC7PYCBX 3021837

Equivalent

Front Track Shock (FTS) FTS Spring Rate lbs/in (N/mm) FTS Spring Installed Length in (cm) Rear Track Shock (RTS) Rear Travel in (cm) Torsion Springs

IQ Switchback 144 Fox HPG w/IFP (Rebuildable) 170 (30) 7.25 (16.4) Fox HPG w/IFP Compression Adjustable (Rebuildable) 16.5 (41.9) .359 Square 77°

Table 1-37: Track Width - Inches (cm)

15 (38)

Length - Inches (cm)

144 (366)

Lug Height - Inches (cm) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

1.25 (3.175)

3/8″ - 1/2″ (1 - 1.3cm)

Table 1-38: Front Suspension Suspension Type Shocks Spring Rate lbs/in (N/mm)

IQ Ryde FX HPG w/IFP (Rebuildable) 120 (21)

Spring Installed Length in (cm)

11.2 (28.4)

Front Vertical Travel in (cm)

9.92 (25.2)

Ski Center Distance in (cm)

42.5 (108)

Camber - in (cm)

2.25 ± 0.31 (57.2 ± 0.79)

Toe Out - in (cm)

0 - 0.12 (0 - 0.31)

FS / FST Service Manual 9921066

1.11

1


Model Specifications 2007 FST IQ

Table 1-42: General

Model Numbers: S07PP7FS / S07PP7FSA / S07PP7FE Table 1-40: Engine Engine Type

8 Valve - SOHC - Parallel Twin Cylinder w/ Counter Balancer

Displacement

749cc

Bore (inches/mm)

3.45 / 85

Stroke (inches/mm)

2.60 / 66

Piston to Cylinder Clearance (inches/mm) Ring Installed End-Gap Top Ring Middle Ring Oil Control Ring (inches / mm)

Width (in/cm)

48 / 121.9

Length (in/cm)

115 / 292.1

Height (in/cm)

48 / 121.9

Estimated Dry Weight (lb/kg)

585 / 265

Fuel (Gallons / Liters)

10.2 / 38.6

Engine Oil - PS4 Plus Equivalent = 0W-50 Synthetic SL Minimum Rating

0.0006-0.002 / 0.017-0.052

2876244 (Quart) 2875522 (Kit) Kit includes 3 quarts oil, filter, o-ring, and ignition jumper.

Oil qts/l 0.009-0.019 / 0.25-0.50 0.007 - 0.013 / 0.20 - 0.35 0.005 - 0.011 / 0.15 - 0.30

3 / 2.8

Coolant qts/l

6.34 / 6.0

Brake Fluid

DOT 4

Oil Filter

0451848

Operating RPM ±200

8000

Air Filter

5812801

Idle RPM

1550

Oil Breather Foam

5812950

Engagement RPM ±200

3800

Drive Belt Part Number Width (inches / cm) Side Angle Ride Out Circumference (inches / cm) Center Distance (inches / cm)

Table 1-41: Clutching ALTITUDE meters (feet)

DRIVE CLUTCH Shift Weight

Clutch Spring

LW DRIVEN CLUTCH Clutch Spring

Driven Helix

Gearing

0-600 (0-2000) 600-1200 (2000-4000)

3121 100/340

24:40-78

11-66 1200-1800 (4000-6000) RED/BLK 1800-2400 (6000-8000) 2400-3000 (8000-10,000)

64/38-.65 NON ER

BLK/GRN 11-64CS

23:46-80

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

3000-3600 (10,000-12,000)

3211121 1.46 / 3.71 26_ .09 / 2.3mm 45.79 / 116.3 11 / 28 8.42 24 40 78 Polaris Synthetic 9 / 266.2 Perc 4

Table 1-43: Fuel Delivery

Drive Clutch Bolt Torque 50 Ft.Lbs. (68Nm)

Type Throttle Body Marking

1253519-01

Throttle Body Bore

39mm

TPS Voltage @ Idle

0.585 Vdc

Fuel Pressure PSI (bar) + Boost Recommended Fuel Octane (R+M/2)

1.12

Sequential Fuel Injection

FS / FST Service Manual 9921066

43.5 (3.0) + Boost 87 (Reduced Performance) 91,92,93 (Recommended)


Model Specifications Table 1-44: Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total) Watts @ 13.5 Vdc (After EMS) Amps @ 13.5 Vdc (No Load)

Table 1-47: Rear Suspension Suspension Type

13.5 - 14.5 Vdc 780 630 60

Ignition Timing

Variable

Spark Plug Gap in.(mm)

.030 (.75)

Spark Plug OE

Champion RC7PYC 04513967 Champion RC7PYCBX 3021837

Equivalent

Front Track Shock (FTS)

Ryde FX HPG w/IFP (Rebuildable)

FTS Spring Rate lbs/in (N/mm)

130 (270)

FTS Spring Installed Length in (cm)

7.72 (19.6)

Rear Track Shock (RTS) Rear Travel in (cm) Torsion Springs

1

IQ 121

Fox PS5 (Rebuildable) 13.9 (35.3) .347 Square - 80°

Table 1-45: Track Width - Inches (cm)

15 (38)

Length - Inches (cm)

121 (307.3)

Lug Height - Inches (cm) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

1 (2.54) 7/8″- 1 1/8″ (2.2 - 2.9cm)

Table 1-46: Front Suspension Suspension Type Shocks Spring Rate lbs/in (N/mm) Spring Installed Length in (cm)

IQ Ryde FX HPG w/IFP (Rebuildable) 120 (21) 10.92 (27.7)

Front Vertical Travel in (cm)

10 (25.4)

Ski Center Distance in (cm)

42.5 (108)

Camber - in (cm)

2.25 ± 0.31 (57.2 ±0.79)

Toe Out - in (cm)

0 - 0.12 (0 - 0.31)

FS / FST Service Manual 9921066

1.13


Model Specifications 2007 FST IQ LX

Table 1-50: General

Model Number: S07PD7FS Table 1-48: Engine Engine Type

8 Valve - SOHC - Parallel Twin Cylinder w/ Counter Balancer

Displacement

749cc

Bore (inches/mm)

3.45 / 85

Stroke (inches/mm)

2.60 / 66

Piston to Cylinder Clearance (inches/mm) Ring Installed End-Gap Top Ring Middle Ring Oil Control Ring (inches / mm)

Width (in/cm)

48 / 121.9

Length (in/cm)

115 / 292.1

Height (in/cm)

48 / 121.9

Estimated Dry Weight (lb/kg)

600 / 272

Fuel (Gallons / Liters)

10.2 / 38.6

Engine Oil - PS4 Plus Equivalent = 0W-50 Synthetic SL Minimum Rating

0.0006-0.002 / 0.017-0.052

2876244 (Quart) 2875522 (Kit) Kit includes 3 quarts oil, filter, o-ring, and ignition jumper.

Oil qts/l 0.009-0.019 / 0.25-0.50 0.007 - 0.013 / 0.20 - 0.35 0.005 - 0.011 / 0.15 - 0.30

3 / 2.8

Coolant qts/l

6.34 / 6.0

Brake Fluid

DOT 4

Oil Filter

0451848

Operating RPM ±200

8000

Air Filter

5812801

Idle RPM

1550

Oil Breather Foam

5812950

Engagement RPM ±200

3800

Drive Belt Part Number Width (inches / cm) Side Angle Ride Out Circumference (inches / cm) Center Distance (inches / cm)

Table 1-49: Clutching ALTITUDE meters (feet)

DRIVE CLUTCH Shift Weight

Clutch Spring

LW DRIVEN CLUTCH Clutch Spring

Driven Helix

Gearing

0-600 (0-2000) 600-1200 (2000-4000)

3121 100/340

24:40-78

11-66 1200-1800 (4000-6000) RED/BLK 1800-2400 (6000-8000) 2400-3000 (8000-10,000)

64/38-.65 NON ER

BLK/GRN 11-64CS

23:46-80

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

3000-3600 (10,000-12,000)

3211121 1.46 / 3.71 26_ .09 / 2.3mm 45.79 / 116.3 11 / 28 8.42 24 40 78 Polaris Synthetic 9 / 266.2 Perc 4

Table 1-51: Fuel Delivery

Drive Clutch Bolt Torque 50 Ft.Lbs. (68Nm)

Type Throttle Body Marking

1253519-01

Throttle Body Bore

39mm

TPS Voltage @ Idle

0.585 Vdc

Fuel Pressure PSI (bar) + Boost Recommended Fuel Octane (R+M/2)

1.14

Sequential Fuel Injection

FS / FST Service Manual 9921066

43.5 (3.0) + Boost 87 (Reduced Performance) 91,92,93 (Recommended)


Model Specifications Table 1-52: Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total) Watts @ 13.5 Vdc (After EMS) Amps @ 13.5 Vdc (No Load)

Table 1-55: Rear Suspension Suspension Type

13.5 - 14.5 Vdc 780 630 60

Ignition Timing

Variable

Spark Plug Gap in.(mm)

.030 (.75)

Spark Plug OE

Champion RC7PYC 04513967 Champion RC7PYCBX 3021837

Equivalent

Table 1-53: Track Width - Inches (cm)

15 (38)

Length - Inches (cm)

128 (325)

Lug Height - Inches (cm) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

Front Track Shock (FTS) FTS Spring Rate lbs/in (N/mm) FTS Spring Installed Length in (cm)

1

Fast M-10 128 Ryde FX Gas Bag 180 (31) 8.50 (21.6)

Rear Track Shock (RTS)

Fox HPG w/IFP (Rebuildable)

Lower Outer Spring Rate

715 (125)

Lower Inner Spring Rate

425 (74.4)

Upper Spring Rate

273 (48)

Rear Travel in (cm)

13 (33)

1 (2.54) 7/8″- 1 1/8″ (2.2 - 2.9cm)

Table 1-54: Front Suspension Suspension Type Shocks

IQ Ryde FX Gas Bag Compression Adjustable

Spring Rate lbs/in (N/mm)

120 (21)

Spring Installed Length in (cm)

9.95 (25)

Front Vertical Travel in (cm)

10 (25.4)

Ski Center Distance in (cm)

42.5 (108)

Camber - in (cm)

2.25 ± 0.31 (57.2 ± 0.79)

Toe Out - in (cm)

0 - 0.12 (0 - 0.31)

FS / FST Service Manual 9921066

1.15


Model Specifications 2007 FS IQ Touring

Table 1-58: General

Model Numbers: S07PT7ES / S07PT7EE Table 1-56: Engine Engine Type

8 Valve - SOHC - Parallel Twin Cylinder w/ Counter Balancer

Displacement

749cc

Bore (inches/mm)

3.45 / 85

Stroke (inches/mm)

2.60 / 66

Piston to Cylinder Clearance (inches/mm) Ring Installed End-Gap Top Ring Middle Ring Oil Control Ring (inches / mm)

Width (in/cm)

48 / 121.9

Length (in/cm)

115 / 292.1

Height (in/cm)

48 / 121.9

Estimated Dry Weight (lb/kg)

640 / 290

Fuel (Gallons / Liters)

10.2 / 38.6

Engine Oil - PS4 Plus Equivalent = 0W-50 Synthetic SL Minimum Rating

0.0006-0.002 / 0.017-0.052

0.009-0.019 / 0.25-0.50 0.007 - 0.013 / 0.20 - 0.35 0.005 - 0.011 / 0.15 - 0.30

Oil qts/l

3 / 2.8

Coolant qts/l

7 / 6.6

Brake Fluid

DOT 4

Oil Filter

0451848 5813009

Operating RPM ±200

8000

Oil Breather Foam

Idle RPM

1550

Engagement RPM ±200

3500

Drive Belt Part Number Width (inches / cm) Side Angle Circumference (inches / cm) Center Distance (inches / cm)

Table 1-57: Clutching ALTITUDE meters (feet)

DRIVE CLUTCH Shift Weight

0-600 (0-2000)

11-52

600-1200 (2000-4000)

11-50

1200-1800 (4000-6000)

11-46

1800-2400 (6000-8000)

11-44

2400-3000 (8000-10,000)

11-42

3000-3600 (10,000-12,000)

11-40

Clutch Spring

LW DRIVEN CLUTCH Clutch Spring

Driven Helix

Gearing

RED/BLK

62/40.46 (64/40.55) NON ER

21:46-80

3121 60/340

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

3076 40/340

Drive Clutch Bolt Torque 50 Ft.Lbs. (68Nm)

3211099 1.49 / 3.78 28_ 46.063 / 116.9 11 / 28 8.42 21 46 80 Polaris Synthetic 9 / 266.2 Perc 4

Table 1-59: Fuel Delivery Type Throttle Body Marking

Sequential Fuel Injection 1253520-01

Throttle Body Bore

46mm

TPS Voltage @ Idle

0.56 Vdc

Fuel Pressure - PSI (bar)

43.5 (3.0)

Recommended Fuel Octane (R+M/2)

1.16

2876244 (Quart) 2875522 (Kit) Kit includes 3 quarts oil, filter, o-ring, and ignition jumper.

FS / FST Service Manual 9921066

87 (Minimum)


Model Specifications Table 1-60: Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total) Watts @ 13.5 Vdc (After EMS) Amps @ 13.5 Vdc (No Load)

Table 1-63: Rear Suspension Suspension Type

13.5 - 14.5 Vdc 780 630 60

Ignition Timing

Variable

Spark Plug Gap in.(mm)

.030 (.75)

Spark Plug OE

Champion RC7YC 3070195 Champion RC7PYCBX 3021837

Equivalent

Table 1-61: Track Width - Inches (cm)

15 (38)

Length - Inches (cm)

136 (345.4)

Lug Height - Inches (cm) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

Front Track Shock (FTS) FTS Spring Rate lbs/in (N/mm) FTS Spring Installed Length in (cm)

1

Fast M-10 136 Ryde FX Gas Bag 220 8.50 (21.6)

Rear Track Shock (RTS)

Fox HPG w/IFP (Rebuildable)

Lower Outer Spring Rate

715 (125)

Lower Inner Spring Rate

425 (74.4)

Upper Spring Rate

273 (48)

Rear Travel in (cm)

14 (35.6)

1 (2.54) 7/8″- 1 1/8″ (2.2 - 2.9cm)

Table 1-62: Front Suspension Suspension Type Shocks

IQ Ryde FX Gas Bag Compression Adjustable

Spring Rate lbs/in (N/mm)

120 (21)

Spring Installed Length in (cm)

9.95 (25)

Front Vertical Travel in (cm)

10 (25.4)

Ski Center Distance in (cm)

42.5 (108)

Camber - in (cm)

2.25 ± 0.31 (57.2 ± 0.79)

Toe Out - in (cm)

0 - 0.12 (0 - 0.31)

FS / FST Service Manual 9921066

1.17


Model Specifications 2007 FST IQ Touring

Table 1-66: General

Model Numbers: S07PT7FS / S07PT7FE Table 1-64: Engine Engine Type

8 Valve - SOHC - Parallel Twin Cylinder w/ Counter Balancer

Displacement

749cc

Bore (inches/mm)

3.45 / 85

Stroke (inches/mm)

2.60 / 66

Piston to Cylinder Clearance (inches/mm) Ring Installed End-Gap Top Ring Middle Ring Oil Control Ring (inches / mm)

Width (in/cm)

48 / 121.9

Length (in/cm)

115 / 292.1

Height (in/cm)

48 / 121.9

Estimated Dry Weight (lb/kg)

660 / 299

Fuel (Gallons / Liters)

10.2 / 38.6

Engine Oil - PS4 Plus Equivalent = 0W-50 Synthetic SL Minimum Rating

0.0006-0.002 / 0.017-0.052

0.009-0.019 / 0.25-0.50 0.007 - 0.013 / 0.20 - 0.35 0.005 - 0.011 / 0.15 - 0.30

2876244 (Quart) 2875522 (Kit) Kit includes 3 quarts oil, filter, o-ring, and ignition jumper.

Oil qts/l

3 / 2.8

Coolant qts/l

7 / 6.6

Brake Fluid

DOT 4

Oil Filter

0451848

Operating RPM ±200

8000

Air Filter

5812801

Idle RPM

1550

Oil Breather Foam

5812950

Engagement RPM ±200

3800

Drive Belt Part Number Width (inches / cm) Side Angle Ride Out Circumference (inches / cm) Center Distance (inches / cm)

Table 1-65: Clutching ALTITUDE meters (feet)

DRIVE CLUTCH Shift Weight

Clutch Spring

LW DRIVEN CLUTCH Clutch Spring

Driven Helix

Gearing

0-600 (0-2000) 600-1200 (2000-4000)

3121 100/340

24:44-80

11-66 1200-1800 (4000-6000) RED/BLK 1800-2400 (6000-8000) 2400-3000 (8000-10,000)

64/38-.65 NON ER

BLK/GRN 11-64CS

23:46-80

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

3000-3600 (10,000-12,000)

3211121 1.46 / 3.71 26_ .09 / 2.3mm 45.79 / 116.3 11 / 28 8.42 24 44 80 Polaris Synthetic 9 / 266.2 Perc 4

Table 1-67: Fuel Delivery

Drive Clutch Bolt Torque 50 Ft.Lbs. (68Nm)

Type Throttle Body Marking

1253519-01

Throttle Body Bore

39mm

TPS Voltage @ Idle

0.585 Vdc

Fuel Pressure PSI (bar) + Boost Recommended Fuel Octane (R+M/2)

1.18

Sequential Fuel Injection

FS / FST Service Manual 9921066

43.5 (3.0) + Boost 87 (Reduced Performance) 91,92,93 (Recommended)


Model Specifications Table 1-68: Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total) Watts @ 13.5 Vdc (After EMS) Amps @ 13.5 Vdc (No Load)

Table 1-71: Rear Suspension Suspension Type

13.5 - 14.5 Vdc 780 630 60

Ignition Timing

Variable

Spark Plug Gap in.(mm)

.030 (.75)

Spark Plug OE

Champion RC7PYC 04513967 Champion RC7PYCBX 3021837

Equivalent

Table 1-69: Track Width - Inches (cm)

15 (38)

Length - Inches (cm)

136 (345.4)

Lug Height - Inches (cm) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

Front Track Shock (FTS) FTS Spring Rate lbs/in (N/mm) FTS Spring Installed Length in (cm)

1

Fast M-10 136 Ryde FX Gas Bag 220 8.50 (21.6)

Rear Track Shock (RTS)

Fox HPG w/IFP (Rebuildable)

Lower Outer Spring Rate

715 (125)

Lower Inner Spring Rate

425 (74.4)

Upper Spring Rate

273 (48)

Rear Travel in (cm)

14 (35.6)

1 (2.54) 7/8″- 1 1/8″ (2.2 - 2.9cm)

Table 1-70: Front Suspension Suspension Type Shocks

IQ Ryde FX Gas Bag Compression Adjustable

Spring Rate lbs/in (N/mm)

120 (21)

Spring Installed Length in (cm)

9.95 (25)

Front Vertical Travel in (cm)

10 (25.4)

Ski Center Distance in (cm)

42.5 (108)

Camber - in (cm)

2.25 ± 0.31 (57.2 ± 0.079)

Toe Out - in (cm)

0 - 0.12 (0 - 0.31)

FS / FST Service Manual 9921066

1.19


Model Specifications 2007 FST IQ Cruiser

Table 1-74: General

Model Numbers: S07PY7FS / S07PY7FE Table 1-72: Engine Engine Type

8 Valve - SOHC - Parallel Twin Cylinder w/ Counter Balancer

Displacement

749cc

Bore (inches/mm)

3.45 / 85

Stroke (inches/mm)

2.60 / 66

Piston to Cylinder Clearance (inches/mm) Ring Installed End-Gap Top Ring Middle Ring Oil Control Ring (inches / mm)

Width (in/cm)

48 / 121.9

Length (in/cm)

115 / 292.1

Height (in/cm)

48 / 121.9

Estimated Dry Weight (lb/kg)

670 / 304

Fuel (Gallons / Liters)

10.2 / 38.6

Engine Oil - PS4 Plus Equivalent = 0W-50 Synthetic SL Minimum Rating

0.0006-0.002 / 0.017-0.052

0.009-0.019 / 0.25-0.50 0.007 - 0.013 / 0.20 - 0.35 0.005 - 0.011 / 0.15 - 0.30

2876244 (Quart) 2875522 (Kit) Kit includes 3 quarts oil, filter, o-ring, and ignition jumper.

Oil qts/l

3 / 2.8

Coolant qts/l

7 / 6.6

Brake Fluid

DOT 4

Oil Filter

0451848

Operating RPM ±200

8000

Air Filter

5812801

Idle RPM

1550

Oil Breather Foam

5812950

Engagement RPM ±200

3800

Drive Belt Part Number Width (inches / cm) Side Angle Ride Out Circumference (inches / cm) Center Distance (inches / cm)

Table 1-73: Clutching ALTITUDE meters (feet)

DRIVE CLUTCH Shift Weight

Clutch Spring

LW DRIVEN CLUTCH Clutch Spring

Driven Helix

Gearing

0-600 (0-2000) 600-1200 (2000-4000)

3121 100/340

24:44-80

11-66 1200-1800 (4000-6000) RED/BLK 1800-2400 (6000-8000) 2400-3000 (8000-10,000)

64/38-.65 NON ER

BLK/GRN 11-64CS

23:46-80

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

3000-3600 (10,000-12,000)

3211121 1.46 / 3.71 26_ .09 / 2.3mm 45.79 / 116.3 11 / 28 8.42 24 44 80 Polaris Synthetic 9 / 266.2 Perc 4

Table 1-75: Fuel Delivery

Drive Clutch Bolt Torque 50 Ft.Lbs. (68Nm)

Type Throttle Body Marking

1253519-01

Throttle Body Bore

39mm

TPS Voltage @ Idle

0.585 Vdc

Fuel Pressure PSI (bar) + Boost Recommended Fuel Octane (R+M/2)

1.20

Sequential Fuel Injection

FS / FST Service Manual 9921066

43.5 (3.0) + Boost 87 (Reduced Performance) 91,92,93 (Recommended)


Model Specifications Table 1-76: Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total) Watts @ 13.5 Vdc (After EMS) Amps @ 13.5 Vdc (No Load)

Table 1-79: Rear Suspension Suspension Type

13.5 - 14.5 Vdc 780 630 60

Ignition Timing

Variable

Spark Plug Gap in.(mm)

.030 (.75)

Spark Plug OE

Champion RC7PYC 04513967 Champion RC7PYCBX 3021837

Equivalent

Table 1-77: Track Width - Inches (cm)

15 (38)

Length - Inches (cm)

136 (345.4)

Lug Height - Inches (cm) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

Front Track Shock (FTS) FTS Spring Rate lbs/in (N/mm) FTS Spring Installed Length in (cm)

Fast M-10 136 ACE Ryde FX Gas Bag 220 8.50 (31.6)

Mid Track Shock

Nitrex Gas Bag

Rear Track Shock (RTS)

Fox HPG w/IFP (Rebuildable)

Lower Outer Spring Rate

715 (125)

Lower Inner Spring Rate

425 (74.4)

Upper Spring Rate

273 (48)

Rear Travel in (cm)

14 (35.6)

1 (2.54) 7/8″- 1 1/8″ (2.2 - 2.9cm)

Table 1-78: Front Suspension Suspension Type Shocks

IQ Ryde FX Gas Bag Compression Adjustable

Spring Rate lbs/in (N/mm)

120 (21)

Spring Installed Length in (cm)

9.95 (25)

Front Vertical Travel in (cm)

10 (25.4)

Ski Center Distance in (cm)

42.5 (108)

Camber - in (cm)

2.25 ± 0.31 (57.2 ± 0.79)

Toe Out - in (cm)

0 - 0.12 (0 - 0.31)

FS / FST Service Manual 9921066

1.21

1


Model Specifications 2007 FST IQ Switchback

Table 1-82: General

Model Numbers: S07PS7FS / S07PS7FE Table 1-80: Engine Engine Type

8 Valve - SOHC - Parallel Twin Cylinder w/ Counter Balancer

Displacement

749cc

Bore (inches/mm)

3.45 / 85

Stroke (inches/mm)

2.60 / 66

Piston to Cylinder Clearance (inches/mm) Ring Installed End-Gap Top Ring Middle Ring Oil Control Ring (inches / mm)

Width (in/cm)

48 / 121.9

Length (in/cm)

115 / 292.1

Height (in/cm)

48 / 121.9

Estimated Dry Weight (lb/kg)

600 / 272

Fuel (Gallons / Liters)

10.2 / 38.6

Engine Oil - PS4 Plus Equivalent = 0W-50 Synthetic SL Minimum Rating

0.0006-0.002 / 0.017-0.052

2876244 (Quart) 2875522 (Kit) Kit includes 3 quarts oil, filter, o-ring, and ignition jumper.

Oil qts/l 0.009-0.019 / 0.25-0.50 0.007 - 0.013 / 0.20 - 0.35 0.005 - 0.011 / 0.15 - 0.30

3 / 2.8

Coolant qts/l

6.34 / 6.0

Brake Fluid

DOT 4

Oil Filter

0451848

Operating RPM ±200

8000

Air Filter

5812801

Idle RPM

1550

Oil Breather Foam

5812950

Engagement RPM ±200

3800

Drive Belt Part Number Width (inches / cm) Side Angle Ride Out Circumference (inches / cm) Center Distance (inches / cm)

Table 1-81: Clutching ALTITUDE meters (feet)

DRIVE CLUTCH Shift Weight

Clutch Spring

LW DRIVEN CLUTCH Clutch Spring

Driven Helix

Gearing

0-600 (0-2000) 600-1200 (2000-4000)

3121 100/340

24:40-78

11-66 1200-1800 (4000-6000) RED/BLK 1800-2400 (6000-8000) 2400-3000 (8000-10,000)

64/38-.65 NON ER

BLK/GRN 11-64CS

23:46-80

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

3000-3600 (10,000-12,000)

3211121 1.46 / 3.71 26_ .09 / 2.3mm 45.79 / 116.3 11 / 28 8.42 24 40 78 Polaris Synthetic 9 / 266.2 Perc 4

Table 1-83: Fuel Delivery

Drive Clutch Bolt Torque 50 Ft.Lbs. (68Nm)

Type Throttle Body Marking

1253519-01

Throttle Body Bore

39mm

TPS Voltage @ Idle

0.585 Vdc

Fuel Pressure PSI (bar) + Boost Recommended Fuel Octane (R+M/2)

1.22

Sequential Fuel Injection

FS / FST Service Manual 9921066

43.5 (3.0) + Boost 87 (Reduced Performance) 91,92,93 (Recomended)


Model Specifications Table 1-84: Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total) Watts @ 13.5 Vdc (After EMS) Amps @ 13.5 Vdc (No Load)

Table 1-87: Rear Suspension Suspension Type

13.5 - 14.5 Vdc 780 630 60

Ignition Timing

Variable

Spark Plug Gap in.(mm)

.030 (.75)

Spark Plug OE

Champion RC7PYC 04513967 Champion RC7PYCBX 3021837

Equivalent

Front Track Shock (FTS) FTS Spring Rate lbs/in (N/mm) FTS Spring Installed Length in (cm) Rear Track Shock (RTS) Rear Travel in (cm) Torsion Springs

IQ Switchback 144 Fox HPG w/IFP (Rebuildable) 170 (30) 7.25 (18.4) Fox HPG w/IFP / Compression Adjustable (Rebuildable) 16.5 (41.9) .359 Square - 77°

Table 1-85: Track Width - Inches (cm)

15 (38)

Length - Inches (cm)

144 (365.7)

Lug Height - Inches (cm)

1.25 (3.175)

Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

3/8″ - 1/2″ (1 - 1.3cm)

Table 1-86: Front Suspension Suspension Type Shocks Spring Rate lbs/in (N/mm)

IQ Fox HPG w/IFP (Rebuildable) 120 (21)

Spring Installed Length in (cm)

11.17 (28)

Front Vertical Travel in (cm)

10 (25.4)

Ski Center Distance in (cm)

42.5 (108)

Camber - in (cm)

2.25 ± 0.31 (57.2 ± 0.79)

Toe Out - in (cm)

0 - 0.12 (0 - 0.31)

FS / FST Service Manual 9921066

1.23

1


Model Specifications 2008 IQ Turbo Dragon

Table 1-90: General

Model Numbers: S08PP7FS / S08PP7FE Table 1-88: Engine Engine Type

8 Valve - SOHC - Parallel Twin Cylinder w/ Counter Balancer

Displacement

749cc

Bore (inches/mm)

3.45 / 85

Stroke (inches/mm)

2.60 / 66

Piston to Cylinder Clearance (inches/mm) Ring Installed End-Gap Top Ring Middle Ring Oil Control Ring (inches / mm)

Width (in/cm)

48 / 121.9

Length (in/cm)

115 / 292.1

Height (in/cm)

48.5 / 123.2

Estimated Dry Weight (lb/kg)

585 / 265

Fuel (Gallons / Liters)

10.2 / 38.6

Engine Oil - PS4 Plus Equivalent = 0W-50 Synthetic SL Minimum Rating

0.0006-0.002 / 0.017-0.052

2876244 (Quart) 2875522 (Kit) Kit includes 3 quarts oil, filter, o-ring, and ignition jumper.

Oil qts/l 0.009-0.019 / 0.25-0.50 0.007 - 0.013 / 0.20 - 0.35 0.005 - 0.011 / 0.15 - 0.30

3 / 2.8

Coolant qts/l

6.34 / 6.0

Brake Fluid

DOT 4

Oil Filter

0451848

Operating RPM ±200

8000

Air Filter

5812801

Idle RPM

1550

Oil Breather Foam

5812950

Engagement RPM ±200

3800

Drive Belt Part Number Width (inches / cm) Side Angle Ride Out Circumference (inches / cm) Center Distance (inches / cm)

Table 1-89: Clutching ALTITUDE meters (feet)

DRIVE CLUTCH Shift Weight

Clutch Spring

LW DRIVEN CLUTCH Clutch Spring

Driven Helix

Gearing

0-600 (0-2000) 600-1200 (2000-4000)

3121 100/340

24:40-78

11-66 1200-1800 (4000-6000) RED/BLK 1800-2400 (6000-8000) 2400-3000 (8000-10,000)

64/38-.65 NON ER

BLK/GRN 11-64CS

23:46-80

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

3000-3600 (10,000-12,000)

3211121 1.46 / 3.71 26_ .09 / 2.3mm 45.79 / 116.3 11 / 28 8.42 24 40 78 Polaris Synthetic 9 / 266.2 Perc 4

Table 1-91: Fuel Delivery

Drive Clutch Bolt Torque 50 Ft.Lbs. (68Nm)

Type Throttle Body Marking

1253519-01

Throttle Body Bore

39mm

TPS Voltage @ Idle

0.585 Vdc

Fuel Pressure PSI (bar) + Boost Recommended Fuel Octane (R+M/2)

1.24

Sequential Fuel Injection

FS / FST Service Manual 9921066

43.5 (3.0) + Boost 87 (Reduced Performance) 91,92,93 (Recomended)


Model Specifications Table 1-92: Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total) Watts @ 13.5 Vdc (After EMS) Amps @ 13.5 Vdc (No Load)

1

13.5 - 14.5 Vdc 780 630 60

Ignition Timing

Variable

Spark Plug Gap in.(mm)

.030 (.75) Champion RC7PYCBX 3021837

Spark Plug

Table 1-93: Track Width - Inches (cm)

15 (38)

Length - Inches (cm)

121 (307.3)

Lug Height - Inches (cm)

1.25 (3.175)

Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

7/8″- 1 1/8″ (2.2 - 2.9cm)

Front Suspension Suspension Type

IQ 42.5

Shocks

Ryde FX Air 2.0

Air 2.0 Nitrogen Pressure 36mm Cylinder 47mm Cylinder

145 psi 60 psi

Front Vertical Travel Inches (cm)

10 (25.4)

Ski Center Distance Inches (cm) Setup Width

42.5 (108) 41.16 (104.5)

Camber Inches (cm)

2.25 ± 0.31 (57.2 ± 0.79)

Toe Out Inches (cm)

0 - 0.12 (0 - 0.31)

Rear Suspension Suspension Type Front Track Shock (FTS) FTS Spring Rate lbs/in (N/mm) FTS Spring Installed Length - Inches (cm)

IQ 121 Ryde FX HPG w/IFP 130 - 270 (23 - 47) 7.72 (19.6)

Rear Track Shock (RTS)

Ryde FX Compression Adj. w/ Remote Res.

Torsion Spring Diameter Tail Angle

.359 Square 80_

Rear Travel Inches (cm)

13.9 (35.3)

FS / FST Service Manual 9921066

1.25


Model Specifications 2008 IQ Turbo LX

Table 1-96: General

Model Numbers: S08PD7FS Table 1-94: Engine Engine Type

8 Valve - SOHC - Parallel Twin Cylinder w/ Counter Balancer

Displacement

749cc

Bore (inches/mm)

3.45 / 85

Stroke (inches/mm)

2.60 / 66

Piston to Cylinder Clearance (inches/mm) Ring Installed End-Gap Top Ring Middle Ring Oil Control Ring (inches / mm)

Width (in/cm)

48 / 121.9

Length (in/cm)

115 / 292.1

Height (in/cm)

48.5 / 129.5

Estimated Dry Weight (lb/kg)

600 / 272

Fuel (Gallons / Liters)

10.2 / 38.6

Engine Oil - PS4 Plus Equivalent = 0W-50 Synthetic SL Minimum Rating

0.0006-0.002 / 0.017-0.052

0.009-0.019 / 0.25-0.50 0.007 - 0.013 / 0.20 - 0.35 0.005 - 0.011 / 0.15 - 0.30

2876244 (Quart) 2875522 (Kit) Kit includes 3 quarts oil, filter, o-ring, and ignition jumper.

Oil qts/l

3 / 2.8

Coolant qts/l

6.34 / 6

Brake Fluid

DOT 4

Oil Filter

0451848

Operating RPM ±200

8000

Air Filter

5812801

Idle RPM

1550

Oil Breather Foam

5812950

Engagement RPM ±200

3800

Drive Belt Part Number Width (inches / cm) Side Angle Ride Out Circumference (inches / cm) Center Distance (inches / cm)

Table 1-95: Clutching ALTITUDE meters (feet)

DRIVE CLUTCH Shift Weight

Clutch Spring

LW DRIVEN CLUTCH Clutch Spring

Driven Helix

Gearing

0-600 (0-2000) 600-1200 (2000-4000)

3121 100/340

24:40-78

11-66 1200-1800 (4000-6000) RED/BLK 1800-2400 (6000-8000) 2400-3000 (8000-10,000)

64/38-.65 NON ER

BLK/GRN 11-64CS

23:46-80

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

3000-3600 (10,000-12,000)

3211121 1.46 / 3.71 26_ .09 / 2.3mm 45.79 / 116.3 11 / 28 8.42 24 40 78 Polaris Synthetic 9 / 266.2 Perc 4

Table 1-97: Fuel Delivery

Drive Clutch Bolt Torque 50 Ft.Lbs. (68Nm)

Type Throttle Body Marking

1253519-01

Throttle Body Bore

39mm

TPS Voltage @ Idle

0.585 Vdc

Fuel Pressure PSI (bar) + Boost Recommended Fuel Octane (R+M/2)

1.26

Sequential Fuel Injection

FS / FST Service Manual 9921066

43.5 (3.0) + Boost 87 (Reduced Performance) 91,92,93 (Recomended)


Model Specifications Table 1-98: Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total) Watts @ 13.5 Vdc (After EMS) Amps @ 13.5 Vdc (No Load)

Table 1-101: Rear Suspension

13.5 - 14.5 Vdc 780 630 60

Ignition Timing

Variable

Spark Plug Gap in.(mm)

.030 (.75) Champion RC7PYCBX 3021837

Spark Plug

Table 1-99: Track

Suspension Type

Fast M-10 128

Front Track Shock (FTS)

Ryde FX MPV

FTS Spring Rate lbs/in (N/mm)

180 (31.5)

FTS Spring Installed Length in (cm)

8.5 (21.6)

Rear Track Shock (RTS)

Fox HPG w/IFP Remote Reservoir

Lower Outer Spring Rate

715 (125)

Lower Inner Spring Rate

425 (74.4)

Width - Inches (cm)

15 (38)

Upper Spring Rate

273 (48)

Length - Inches (cm)

128 ()

Rear Travel in (cm)

13 (33)

Lug Height - Inches (cm) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

1

1 (2.54) 7/8″- 1 1/8″ (2.2 - 2.9cm)

Table 1-100: Front Suspension Suspension Type Shocks

IQ 42.5 Ryde FX MPV

Spring Rate lbs/in (N/mm)

120 (21)

Spring Installed Length in (cm)

9.95 (25)

Front Vertical Travel in (cm)

10 (25.4)

Ski Center Distance Inches (cm) Setup Width

42.5 (108) 41.16 (104.5)

Camber - in (cm)

2.25 ± 0.31 (57.2 ± 0.79)

Toe Out - in (cm)

0 - 0.12 (0 - 0.31)

FS / FST Service Manual 9921066

1.27


Model Specifications 2008 Turbo Switchback

Table 1-104: General

Model Numbers: S08PR7FS / S08PR7FE Table 1-102: Engine Engine Type

8 Valve - SOHC - Parallel Twin Cylinder w/ Counter Balancer

Displacement

749cc

Bore (inches/mm)

3.45 / 85

Stroke (inches/mm)

2.60 / 66

Piston to Cylinder Clearance (inches/mm) Ring Installed End-Gap Top Ring Middle Ring Oil Control Ring (inches / mm)

Width (in/cm)

48 / 121.9

Length (in/cm)

120 / 308.4

Height (in/cm)

48.5 / 123.2

Estimated Dry Weight (lb/kg)

605 / 274

Fuel (Gallons / Liters)

10.2 / 38.6

Engine Oil - PS4 Plus Equivalent = 0W-50 Synthetic SL Minimum Rating

0.0006-0.002 / 0.017-0.052

2876244 (Quart) 2875522 (Kit) Kit includes 3 quarts oil, filter, o-ring, and ignition jumper.

Oil qts/l 0.009-0.019 / 0.25-0.50 0.007 - 0.013 / 0.20 - 0.35 0.005 - 0.011 / 0.15 - 0.30

3 / 2.8

Coolant qts/l

8.8 / 8.3

Brake Fluid

DOT 4

Oil Filter

0451848

Operating RPM ±200

8000

Air Filter

5812801

Idle RPM

1550

Oil Breather Foam

5812950

Engagement RPM ±200

3800

Drive Belt Part Number Width (inches / cm) Side Angle Ride Out Circumference (inches / cm) Center Distance (inches / cm)

Table 1-103: Clutching ALTITUDE meters (feet)

DRIVE CLUTCH Shift Weight

Clutch Spring

LW DRIVEN CLUTCH Clutch Spring

Driven Helix

Gearing

0-600 (0-2000) 600-1200 (2000-4000)

3121 100/340

24:40-78

11-66 1200-1800 (4000-6000) RED/BLK 1800-2400 (6000-8000) 2400-3000 (8000-10,000)

64/38-.65 NON ER

BLK/GRN 11-64CS

23:46-80

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

3000-3600 (10,000-12,000)

3211121 1.46 / 3.71 26_ .09 / 2.3mm 45.79 / 116.3 11 / 28 8.42 24 40 78 Polaris Synthetic 9 / 266.2 Perc 4

Table 1-105: Fuel Delivery

Drive Clutch Bolt Torque 50 Ft.Lbs. (68Nm)

Type Throttle Body Marking

1253519-01

Throttle Body Bore

39mm

TPS Voltage @ Idle

0.585 Vdc

Fuel Pressure PSI (bar) + Boost Recommended Fuel Octane (R+M/2)

1.28

Sequential Fuel Injection

FS / FST Service Manual 9921066

43.5 (3.0) + Boost 87 (Reduced Performance) 91,92,93 (Recomended)


Model Specifications Table 1-106: Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total) Watts @ 13.5 Vdc (After EMS) Amps @ 13.5 Vdc (No Load)

Table 1-109: Rear Suspension Suspension Type

13.5 - 14.5 Vdc 780 630 60

Ignition Timing

Variable

Spark Plug Gap in.(mm)

.030 (.75) Champion RC7PYCBX 3021837

Spark Plug

Front Track Shock (FTS) FTS Spring Rate lbs/in (N/mm) FTS Spring Installed Length in (cm) Rear Track Shock (RTS) Rear Travel in (cm) Torsion Springs

1

IQ 136 Coupled Ryde FX HPG w/IFP 130 - 270 (22 - 47) 7.72 (19.6) Fox PS-5 14 (53) .359 Square - 80°

Table 1-107: Track Width - Inches (cm)

15 (38)

Length - Inches (cm)

136 (345.4)

Lug Height - Inches (cm)

1.25 (3.175)

Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

7/8″- 1 1/8″ (2.2 - 2.9cm)

Table 1-108: Front Suspension Suspension Type Shocks Spring Rate lbs/in (N/mm) Spring Installed Length in (cm) Front Vertical Travel in (cm) Ski Center Distance Inches (cm) Setup Width

IQ 42.5 Ryde FX HPG w/IFP 120 (21) 10.92 (27.7) 10 (25.4)

42.5 (108) 41.16 (104.5)

Camber - in (cm)

2.25 ± 0.31 (57.2 ± 0.79)

Toe Out - in (cm)

0 - 0.12 (0 - 0.31)

FS / FST Service Manual 9921066

1.29


Model Specifications 2008 FS IQ Touring

Table 1-112: General

Model Numbers: S08PT7ES / S08PT7EE Table 1-110: Engine Engine Type

8 Valve - SOHC - Parallel Twin Cylinder w/ Counter Balancer

Displacement

749cc

Bore (inches/mm)

3.45 / 85

Stroke (inches/mm)

2.60 / 66

Piston to Cylinder Clearance (inches/mm) Ring Installed End-Gap Top Ring Middle Ring Oil Control Ring (inches / mm)

Width (in/cm)

48 / 121.9

Length (in/cm)

129 / 327.7

Height (in/cm)

53 / 134.6

Estimated Dry Weight (lb/kg)

640 / 290

Fuel (Gallons / Liters)

10.2 / 38.6

Engine Oil - PS4 Plus Equivalent = 0W-50 Synthetic SL Minimum Rating

0.0006-0.002 / 0.017-0.052

0.009-0.019 / 0.25-0.50 0.007 - 0.013 / 0.20 - 0.35 0.005 - 0.011 / 0.15 - 0.30

Oil qts/l

3 / 2.8

Coolant qts/l

7 / 6.6

Brake Fluid

DOT 4

Oil Filter

0451848 5813009

Operating RPM ±200

8000

Oil Breather Foam

Idle RPM

1550

Engagement RPM ±200

3500

Drive Belt Part Number Width (inches / cm) Side Angle Circumference (inches / cm) Center Distance (inches / cm)

Table 1-111: Clutching ALTITUDE meters (feet)

DRIVE CLUTCH Shift Weight

0-600 (0-2000)

11-52

600-1200 (2000-4000)

11-50

1200-1800 (4000-6000)

11-46

1800-2400 (6000-8000)

11-44

2400-3000 (8000-10,000)

11-42

3000-3600 (10,000-12,000)

11-40

Clutch Spring

LW DRIVEN CLUTCH Clutch Spring

Driven Helix

Gearing

RED/BLK

62/40.46 (64/40.55) NON ER

21:46-80

3121 60/340

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

3076 40/340

Drive Clutch Bolt Torque 50 Ft.Lbs. (68Nm)

3211099 1.49 / 3.78 28_ 46.063 / 116.9 11 / 28 8.42 21 46 80 Polaris Synthetic 9 / 266.2 Perc 4

Table 1-113: Fuel Delivery Type Throttle Body Marking

Sequential Fuel Injection 1253520-01

Throttle Body Bore

46mm

TPS Voltage @ Idle

0.56 Vdc

Fuel Pressure - PSI (bar)

43.5 (3.0)

Recommended Fuel Octane (R+M/2)

1.30

2876244 (Quart) 2875522 (Kit) Kit includes 3 quarts oil, filter, o-ring, and ignition jumper.

FS / FST Service Manual 9921066

87 (Minimum)


Model Specifications Table 1-114: Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total) Watts @ 13.5 Vdc (After EMS) Amps @ 13.5 Vdc (No Load)

Table 1-117: Rear Suspension

13.5 - 14.5 Vdc 780 630 60

Ignition Timing

Variable

Spark Plug Gap in.(mm)

.030 (.75) Champion RC7PYCBX 3021837

Spark Plug

Suspension Type

IQ 136 Comfort

Front Track Shock (FTS)

Ryde FX MPV

FTS Spring Rate lbs/in (N/mm) FTS Spring Installed Length in (cm) Rear Track Shock (RTS) Rear Travel in (cm) Torsion Springs

1

275 (48) 8.74 (22.2) Ryde FX MPV 14 (35.6) .405 Square - 80°

Table 1-115: Track Width - Inches (cm)

15 (38)

Length - Inches (cm)

136 (345.4)

Lug Height - Inches (cm) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

1 (2.54) 7/8″- 1 1/8″ (2.2 - 2.9cm)

Table 1-116: Front Suspension Suspension Type Shocks

IQ 42.5 Ryde FX MPV

Spring Rate lbs/in (N/mm)

140 (24.5)

Spring Installed Length in (cm)

9.95 (25.2)

Front Vertical Travel in (cm) Ski Center Distance Inches (cm) Setup Width

10 (25.4)

42.5 (108) 41.16 (104.5)

Camber - in (cm)

2.25 ± 0.31 (57.2 ± 0.79)

Toe Out - in (cm)

0 - 0.12 (0 - 0.31)

FS / FST Service Manual 9921066

1.31


Model Specifications 2008 FST IQ Touring

Table 1-120: General

Model Numbers: S08PT7FS / S08PT7FE Table 1-118: Engine Engine Type

8 Valve - SOHC - Parallel Twin Cylinder w/ Counter Balancer

Displacement

749cc

Bore (inches/mm)

3.45 / 85

Stroke (inches/mm)

2.60 / 66

Piston to Cylinder Clearance (inches/mm) Ring Installed End-Gap Top Ring Middle Ring Oil Control Ring (inches / mm)

Width (in/cm)

48 / 121.9

Length (in/cm)

129 / 327.7

Height (in/cm)

53 / 134.6

Estimated Dry Weight (lb/kg)

660 / 299

Fuel (Gallons / Liters)

10.2 / 38.6

Engine Oil - PS4 Plus Equivalent = 0W-50 Synthetic SL Minimum Rating

0.0006-0.002 / 0.017-0.052

0.009-0.019 / 0.25-0.50 0.007 - 0.013 / 0.20 - 0.35 0.005 - 0.011 / 0.15 - 0.30

2876244 (Quart) 2875522 (Kit) Kit includes 3 quarts oil, filter, o-ring, and ignition jumper.

Oil qts/l

3 / 2.8

Coolant qts/l

7 / 6.6

Brake Fluid

DOT 4

Oil Filter

0451848

Operating RPM ±200

8000

Air Filter

5812801

Idle RPM

1550

Oil Breather Foam

5812950

Engagement RPM ±200

3800

Drive Belt Part Number Width (inches / cm) Side Angle Ride Out Circumference (inches / cm) Center Distance (inches / cm)

Table 1-119: Clutching ALTITUDE meters (feet)

DRIVE CLUTCH Shift Weight

Clutch Spring

LW DRIVEN CLUTCH Clutch Spring

Driven Helix

Gearing

0-600 (0-2000) 600-1200 (2000-4000)

3121 100/340

24:44-80

11-66 1200-1800 (4000-6000) RED/BLK 1800-2400 (6000-8000) 2400-3000 (8000-10,000)

64/38-.65 NON ER

BLK/GRN 11-64CS

23:46-80

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

3000-3600 (10,000-12,000)

3211121 1.46 / 3.71 26_ .09 / 2.3mm 45.79 / 116.3 11 / 28 8.42 24 44 80 Polaris Synthetic 9 / 266.2 Perc 4

Table 1-121: Fuel Delivery

Drive Clutch Bolt Torque 50 Ft.Lbs. (68Nm)

Type Throttle Body Marking

1253519-01

Throttle Body Bore

39mm

TPS Voltage @ Idle

0.585 Vdc

Fuel Pressure PSI (bar) + Boost Recommended Fuel Octane (R+M/2)

1.32

Sequential Fuel Injection

FS / FST Service Manual 9921066

43.5 (3.0) + Boost 87 (Reduced Performance) 91,92,93 (Recomended)


Model Specifications Table 1-122: Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total) Watts @ 13.5 Vdc (After EMS) Amps @ 13.5 Vdc (No Load)

Table 1-125: Rear Suspension

13.5 - 14.5 Vdc 780 630 60

Ignition Timing

Variable

Spark Plug Gap in.(mm)

.030 (.75) Champion RC7PYCBX 3021837

Spark Plug

Suspension Type

IQ 136 Comfort

Front Track Shock (FTS)

Ryde FX MPV

FTS Spring Rate lbs/in (N/mm) FTS Spring Installed Length in (cm) Rear Track Shock (RTS) Rear Travel in (cm) Torsion Springs

1

275 (48) 8.74 (22.2) Ryde FX MPV 14 (35.6) .405 Square - 80°

Table 1-123: Track Width - Inches (cm)

15 (38)

Length - Inches (cm)

136 ()

Lug Height - Inches (cm) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

1 (2.54) 7/8″- 1 1/8″ (2.2 - 2.9cm)

Table 1-124: Front Suspension Suspension Type Shocks

IQ 42.5 Ryde FX MPV

Spring Rate lbs/in (N/mm)

140 (24.5)

Spring Installed Length in (cm)

9.95 (25.2)

Front Vertical Travel in (cm) Ski Center Distance Inches (cm) Setup Width

10 (25.4)

42.5 (108) 41.16 (104.5)

Camber - in (cm)

2.25 ± 0.31 (57.2 ± 0.79)

Toe Out - in (cm)

0 - 0.12 (0 - 0.31)

FS / FST Service Manual 9921066

1.33


Model Specifications 2008 IQ Cruiser

Table 1-128: General

Model Numbers: S08PY7FS / S08PY7FE Table 1-126: Engine Engine Type

8 Valve - SOHC - Parallel Twin Cylinder w/ Counter Balancer

Displacement

749cc

Bore (inches/mm)

3.45 / 85

Stroke (inches/mm)

2.60 / 66

Piston to Cylinder Clearance (inches/mm) Ring Installed End-Gap Top Ring Middle Ring Oil Control Ring (inches / mm)

Width (in/cm)

48 / 121.9

Length (in/cm)

129 / 327.7

Height (in/cm)

53 / 134.6

Estimated Dry Weight (lb/kg)

670 / 304

Fuel (Gallons / Liters)

10.2 / 38.6

Engine Oil - PS4 Plus Equivalent = 0W-50 Synthetic SL Minimum Rating

0.0006-0.002 / 0.017-0.052

0.009-0.019 / 0.25-0.50 0.007 - 0.013 / 0.20 - 0.35 0.005 - 0.011 / 0.15 - 0.30

2876244 (Quart) 2875522 (Kit) Kit includes 3 quarts oil, filter, o-ring, and ignition jumper.

Oil qts/l

3 / 2.8

Coolant qts/l

7 / 6.6

Brake Fluid

DOT 4

Oil Filter

0451848

Operating RPM ±200

8000

Air Filter

5812801

Idle RPM

1550

Oil Breather Foam

5812950

Engagement RPM ±200

3800

Drive Belt Part Number Width (inches / cm) Side Angle Ride Out Circumference (inches / cm) Center Distance (inches / cm)

Table 1-127: Clutching ALTITUDE meters (feet)

DRIVE CLUTCH Shift Weight

Clutch Spring

LW DRIVEN CLUTCH Clutch Spring

Driven Helix

Gearing

0-600 (0-2000) 600-1200 (2000-4000)

3121 100/340

24:44-80

11-66 1200-1800 (4000-6000) RED/BLK 1800-2400 (6000-8000) 2400-3000 (8000-10,000)

64/38-.65 NON ER

BLK/GRN 11-64CS

23:46-80

Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System

3000-3600 (10,000-12,000)

3211121 1.46 / 3.71 26_ .09 / 2.3mm 45.79 / 116.3 11 / 28 8.42 24 44 80 Polaris Synthetic 9 / 266.2 Perc 4

Table 1-129: Fuel Delivery

Drive Clutch Bolt Torque 50 Ft.Lbs. (68Nm)

Type Throttle Body Marking

1253519-01

Throttle Body Bore

39mm

TPS Voltage @ Idle

0.585 Vdc

Fuel Pressure PSI (bar) + Boost Recommended Fuel Octane (R+M/2)

1.34

Sequential Fuel Injection

FS / FST Service Manual 9921066

43.5 (3.0) + Boost 87 (Reduced Performance) 91,92,93 (Recomended)


Model Specifications Table 1-130: Electrical Alternator Output Operating Voltage Watts @ 13.5 Vdc (Total) Watts @ 13.5 Vdc (After EMS) Amps @ 13.5 Vdc (No Load)

Table 1-133: Rear Suspension Suspension Type

13.5 - 14.5 Vdc 780 630 60

Ignition Timing

Variable

Spark Plug Gap in.(mm)

.030 (.75) Champion RC7PYCBX 3021837

Spark Plug

Table 1-131: Track

Front Track Shock (FTS)

Fast M-10 136 ACE Ryde FX MPV

FTS Spring Rate lbs/in (N/mm)

220 (38.5)

FTS Spring Installed Length in (cm)

8.5 (21.6)

Rear Track Shock (RTS)

Fox HPG w/IFP Remote Reservoir

Lower Outer Spring Rate

715 (125)

Lower Inner Spring Rate

425 (74.4)

Width - Inches (cm)

15 (38)

Upper Spring Rate

273 (48)

Length - Inches (cm)

136 (345.4)

Rear Travel in (cm)

13 (33)

Lug Height - Inches (cm) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/ 40cm ahead of rear idler shaft

1 (2.54) 7/8″- 1 1/8″ (2.2 - 2.9cm)

Table 1-132: Front Suspension Suspension Type Shocks

IQ 42.5 Ryde FX MPV

Spring Rate lbs/in (N/mm)

120 (21)

Spring Installed Length in (cm)

9.95 (25)

Front Vertical Travel in (cm)

10 (25.4)

Ski Center Distance Inches (cm) Setup Width

42.5 (108) 41.16 (104.5)

Camber - in (cm)

2.25 ± 0.31 (57.2 ± 0.79)

Toe Out - in (cm)

0 - 0.12 (0 - 0.31)

FS / FST Service Manual 9921066

1.35

1


Model Specifications

NOTES

1.36

FS / FST Service Manual 9921066


General Information

CHAPTER 2 General Information VIN (VEHICLE IDENTIFICATION NUMBER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 VIN ORGANIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 TUNNEL DECAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

2

FS / FST PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 2006 PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 2007 PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 2008 PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 MISCELLANEOUS PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 SAE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 METRIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

SAE / METRIC EQUIVALENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

FASTENER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 STANDARD BOLT SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

GASOLINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 GASOLINE VOLATILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

FS / FST Service Manual 9921066

2.1


General Information VIN (VEHICLE IDENTIFICATION NUMBER)

Digits 1-3: World Manufacturer Identifier. For Polaris, this is SN1.

VIN Organization

Digits 4-9: Vehicle Descriptor Section.

A 17-digit Vehicle Identification Number (VIN) is stamped into the right-hand side of the tunnel. The VIN is organized as follows:

Digits 10-17: Vehicle Indicator Section. Digits 4-8 of the VIN identify the body style, type, engine type, and series. The VIN and the model number must be used with any correspondence regarding service or repair.

VIN Vehicle Descriptor (4th - 8th digits) 4th

5th

6th

Body Style

Type

P = IQ

D = Classic P = Performance S = Switchback T = Touring

7th

8th

9th

10th

11

12-17

Engine Modifier

Series

Ck digit

Model Year

Asm Line

Ser #

7E = 750 NA 7F = 750 Turbo

E = Europe S = Standard

Check Digit

6 = 2006 7 = 2007 8 = 2008 9 = 2009

A B C D

Serial Number

TUNNEL DECAL

The VIN should be referred to in any correspondence regarding warranty, service or replacement parts. The machine model and serial number identification decal is located on the right front side of the tunnel. The serial number is permanently stamped into the tunnel. The model number is embossed on the decal.

2.2

FS / FST Service Manual 9921066


General Information FS / FST PUBLICATION PART NUMBERS 2006 Publication Part Numbers

Model Number

Owner’s Manual

Owner’s Manual Supplement

Parts Manual

FS/FST Classic

S06PD7ES / S06PD7FS

9919670

9919692

9919733

FS/FST IQ Touring

S06PT7ES / S06PT7FS

9919673

9919710

9919751

S06PS7FS

9919672

9919708

9919747

Owner’s Manual

Owner’s Manual Supplement

Parts Manual

Model

FST Switchback

Assembly Instruction

Service Manual

9916508

9921066

Assembly Instruction

Service Manual

9920606

9921066

Assembly Instruction

Service Manual

2007 Publication Part Numbers

Model

Model Number

FST IQ LX

S07PD7FS

FST IQ LX LTD

S07PF7FS

FST IQ

S07PP7FS / S07PP7FE

FST IQ Switchback

S07PS7FS / S07PS7FE

FS IQ Touring

S07PT7ES / S07PT7EE

FST IQ Touring

S07PT7FS / S07PT7FE

FST IQ Cruiser

S07PY7FS / S07PY7FE

9920473

9920474

9920488 9920468

9920498

9920499

9920504

9920505

9920507

9920508

Owner’s Manual

Owner’s Manual Supplement

Parts Manual

9921084

9921092

2008 Publication Part Numbers

Model

Model Number

IQ Turbo LX

9921091

S08PD7FS

IQ Turbo Dragon

S08PP7FS / S08PP7FE

Turbo Switchback

S08PR7FS / S08PR7FE

9921093

FS IQ Touring

S08PT7ES / S08PT7EE

9921096

FST IQ Touring

S08PT7FS / S08PT7FE

IQ Cruiser

S08PY7FS / S08PY7FE

9921087

9921086 9921095

9920606

9921066

9921098

9921097 9921099

Miscellaneous Publications Misc. Publications Publication

PN

Track Diagnosis Poster

9918459

FS / FST Service Manual Binder Only

9921004

2006 Specification Handbook/Quick Reference Manual

9920147

Wiring Schematics for 2006 Model Year Sleds

9920672

FS / FST Service Manual 9921066

2.3

2


General Information TAP DRILL SIZES

SAE / METRIC EQUIVALENTS

SAE

Decimal Equivalents

Thread Size/ Drill Size

Thread Size / Drill Size

#0-80

3/64

1/2-13

27/64

#1-64

53

1/2-20

29/64

#1-72

53

9/16-12

31/64

#2-56

51

9/16-18

33/64

#2-64

50

5/8-11

17/32

#3-48

5/64

5/8-18

37/64

#3-56

45

3/4-10

21/32

#4-40

43

3/4-16

11/16

#4-48

42

7/8-9

49/64

#5-40

38

7/8-14

13/16

#5-44

37

1-8

7/8

#6-32

36

1-12

59/64

#6-40

33

1 1/8-7

63/64

#8-32

29

1 1/8-12

1 3/64

#8-36

29

1 1/4-7

1 7/64

#10-24

24

1 1/4-12

1 11/64

#10-32

21

1 1/2-6

1 11/32

#12-24

17

1 1/2-12

1 27/64

#12-28

4.6mm

1 3/4-5

1 9/16

1/4-20

7

1 3/4-12

1 43/64

1/4-28

3

2-4 1/2

1 25/32

5/16-18

F

2-12

1 59/64

5/16-24

I

2 1/4-4 1/2

2 1/32

3/8-16

O

2 1/2-4

2 1/4

3/8-24

Q

2 3/4-4

2 1/2

7/16-14

U

3-4

2 3/4

7/16-20

25/64

Drill Size

Decimal Equivalent

Nearest Fraction

3x.50

#39

0.0995

3/32

3x.60

3/32

0.0937

3/32

4x.70

#30

0.1285

1/8

4x.75

1/8

0.125

1/8

5x.80

#19

0.166

11/64

Metric Tap Size

5x.90

#20

0.161

5/32

6x1.00

#9

0.196

13/64

7x1.00

16/64

0.234

15/64

8x1.00

J

0.277

9/32

8x1.25

17/64

0.265

17/64

9x1.00

5/16

0.3125

5/16

9x1.25

5/16

0.3125

5/16

10x1.25

11/32

0.3437

11/32 11/32

10x1.50

R

0.339

11 x 1.50

3/8

0.375

3/8

12x1.50

13/32

0.406

13/32

12x1.75

13/32

0.406

13/32

2.4

1/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .0156" - - - - - - - - 1/32- - - - - - - - - - - - - - - - - - - - - - - .0312 - - - - - 1 mm= .0394" 3/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .0469 - - - - - - - - 1/16- - - - - - - - - - - - - - - - - - - - - - - .0625 5/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .0781 - - - - - 2 mm = .0787" - - - - - - - - 3/32- - - - - - - - - - - - - - - - - - - - - - - .0938 7/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .1094 - - - - - 3 mm =.1181" - - - - - - - - 1/8 - - - - - - .1250 9/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .1406 - - - - - - - - 5/32- - - - - - - - - - - - - - - - - - - - - - - .1563 - - - - - 4 mm = .1575" 11/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .1719 - - - - - - - - 3/16- - - - - - - - - - - - - - - - - - - - - - - .1875 - - - - - 5mm= .1969" 13/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .2031 - - - - - - - - 7/32- - - - - - - - - - - - - - - - - - - - - - - .2188 15/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .2344 - - - - - 6 mm = .2362" - - - - - - - - 1/4 - - - - - - .25 17/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .2656 - - - - - 7 mm = .2756" - - - - - - - - 9/32- - - - - - - - - - - - - - - - - - - - - - - .2813 19/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .2969 - - - - - - - - 5/16- - - - - - - - - - - - - - - - - - - - - - - .3125 - - - - - 8mm= .3150" 21/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .3281 - - - - - - - - 11/32- - - - - - - - - - - - - - - - - - - - - - .3438 - - - - - 9 mm = .3543" 23/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .3594 - - - - - - - - 3/8 - - - - - - .375 25/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .3906 - - - - - 10 mm = .3937" 13/32 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .4063 27/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .4219 - - - - - 11 mm =.4331" - - - - - - - - 7/16- - - - - - - - - - - - - - - - - - - - - - - .4375 29/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .4531 - - - - - - - - 15/32- - - - - - - - - - - - - - - - - - - - - - .4688 - - - - - 12 mm = .4724" 31/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .4844 - - - - - - - - 1/2 - - - - - - .5- - - - - - - - - - - - - - - - - - - - - - - - - 13mm = .5118" 33/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .5156 - - - - - - - - 17/32- - - - - - - - - - - - - - - - - - - - - - .5313 35/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .5469 - - - - - 14 mm = .5512" - - - - - - - - 9/16- - - - - - - - - - - - - - - - - - - - - - - .5625 37/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .5781 - - - - - 15 mm = .5906" - - - - - - - - 19/32- - - - - - - - - - - - - - - - - - - - - - .5938 39/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .6094 - - - - - - - - 5/8 - - - - - - .625- - - - - - - - - - - - - - - - - - - - - - - 16mm=. 6299" 41/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .6406 - - - - - - - - 21/32- - - - - - - - - - - - - - - - - - - - - - .6563 - - - - - 17 mm =.6693" 43/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .6719 - - - - - - - - 11/16- - - - - - - - - - - - - - - - - - - - - - .6875 45/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .7031 - - - - - 18 mm = .7087" - - - - - - - - 23/32- - - - - - - - - - - - - - - - - - - - - - .7188 47/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .7344 - - - - - 19 mm = .7480" - - - - - - - - 3/4 - - - - - - .75 49/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .7656 - - - - - - - - 25/32- - - - - - - - - - - - - - - - - - - - - - .7813 - - - - - 20 mm = .7874" 51/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .7969 - - - - - - - - 13/16- - - - - - - - - - - - - - - - - - - - - - .8125 - - - - - 21 mm =.8268" 53/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .8281 - - - - - - - - 27/32- - - - - - - - - - - - - - - - - - - - - - .8438 55/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .8594 - - - - - 22 mm = .8661" - - - - - - - - 7/8 - - - - - - .875 57/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .8906 - - - - - 23 mm = .9055" - - - - - - - - 29/32- - - - - - - - - - - - - - - - - - - - - - .9063 59/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .9219 - - - - - - - - 15/16- - - - - - - - - - - - - - - - - - - - - - .9375 - - - - - 24 mm = .9449" 61/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .9531 - - - - - - - - 31/32- - - - - - - - - - - - - - - - - - - - - - .9688 - - - - - 25 mm = .9843" 63/64 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .9844 - - - - - - - - 1 - - - - - - - 1.0

FS / FST Service Manual 9921066


General Information Conversion Table Unit of Measure

Multiplied by

Converts to

ft. lbs.

x12

= in. lbs.

in. lbs.

x .0833

= ft. lbs.

ft. lbs.

x 1.356

= Nm

in. lbs.

x.0115

= kg-m

Nm

x .7376

= ft. lbs.

kg-m

x 7.233

= ft. lbs.

kg-m

x 86.796

= in. lbs.

kg-m

x 9.807

= Nm

in.

x25.4

=mm

mm

x .03937

= in.

in.

x2.54

= cm

mile (mi.)

x1.6

= km

km

x.6214

= mile (mi.)

Ounces (oz)

x 28.35

= Grams (g)

Fluid Ounces (fl. oz.)

x 29.57

= Cubic Centimeters (cc)

Cubic Centimeters (cc)

x .03381

= Fluid Ounces (fl. oz.)

Grams (g)

x 0.035

= Ounces (oz)

lb.

x.454

= kg

kg

x 2.2046

= lb.

Cubic inches (cu in)

x 16.387

= Cubic centimeters (cc)

Cubic centimeters (cc)

x 0.061

= Cubic inches (cu in)

Imperial pints (Imp pt)

x 0.568

= Liters (l)

Liters (l)

x1.76

= Imperial pints (Imp pt)

Imperial quarts (Imp qt)

x 1.137

= Liters (l)

Liters (l)

x0.88

= Imperial quarts (Imp qt)

Imperial quarts (Imp qt)

x 1.201

= US quarts (US qt)

US quarts (US qt)

x 0.833

= Imperial quarts (Imp qt)

US quarts (US qt)

x 0.946

= Liters (l)

Liters (l)

x 1.057

= US quarts (US qt)

US gallons (US gal)

x 3.785

=Liters (l)

Liters (l)

x 0.264

= US gallons (US gal)

Pounds - force per square inch (psi)

x 6.895

= Kilopascals (kPa)

Kilopascals (kPa)

x 0.145

= Pounds - force per square inch (psi)

Kilopascals (kPa)

x0.01

= Kilograms - force per square cm

Kilograms - force per square cm

x98.1

= Kilopascals (kPa)

ð(3.14)xR2xH (height)

2

= Cylinder Volume

°C to °F: 9 (°C + 40)+ 5 - 40 = °F °F to °C: 5 (°F + 40) + 9 - 40 = °C

FS / FST Service Manual 9921066

2.5


General Information FASTENER INFORMATION

or no vaporization will occur. Droplets will form causing flooding and very hard starting.

Standard Bolt Specifications

Grade 2

If winter blend fuel is being used during the summer months, it may cause vapor lock (boiling fuel) inside the fuel lines, fuel pump, or carburetor. This will cause warm engine drive ability problems and hard starting when warm. Some states are limiting the Reid Vapor number to 9.0 PSI year around to help meet Grade 8

Grade 5

The following torque specifications are to be used as a general guideline when torque value is not specified. There are exceptions in the steering, suspension, and engine areas. Always consult the torque chart and the specific manual section for torque values of fasteners.

Standard Bolt Specifications Bolt Size

Threads/ In

Grade 2 ft-lb(Nm)

Grade 5 ft-lb(Nm)

Grade 8 ft-lb(Nm)

1/4

20

5 (7)

8 (11)

12 (16)

1/4

28

6 (8)

10 (14)

14 (19)

5/16

18

11 (15)

17 (23)

25 (35)

5/16

24

12 (16)

19 (26)

29 (40)

3/8

16

20 (27)

30 (40)

45 (62)

3/8

24

23 (32)

35 (48)

50 (69)

7/16

14

30 (40)

50 (69)

70 (97)

7/16

20

35 (48)

55 (76)

80 (110)

1/2

13

50 (69)

75 (104)

110 (152)

1/2

20

55 (76)

90 (124)

120 (166)

evaporative emissions standards.

Gasoline Volatility MAXIMUM REID VAPOR CLASS

PRESSURE

LOW

HIGH

A

7.0 psi (0.5 bar)

60_F (16_C)

110F+ (43_C+)

B

9.0 psi (0.6 bar)

50_F (10_C)

110F (43_C)

C

10.5psi (0.7 bar)

40_F (4_C)

97F (36_C)

D

12.0psi (0.8 bar)

30_F (-1_C)

85F (29_C)

E

13.5psi (0.9 bar)

20_F (-7_C)

69F (21_C)

Add 2.45_F for each 1000 ft (305m) above sea level

ft-lb X 1.356 = Nm Nm X.7376 = ft-lb

GASOLINE INFORMATION GASOLINE VOLATILITY One of the misunderstood properties of gasoline is its volatility, or ability to vaporize at different ambient temperatures and altitudes during the year. When gasoline is blended, it is given a Reid Vapor Pressure (RVP) number which reflects its ability to vaporize or mix with air at a given temperature range. Gasoline vapor pressure is measured by putting a sample of fuel inside a closed container and applying a specified amount of heat to the container for a certain amount of time. RVP will vary from about 7.0 PSI during the summer to approximately 13.5 PSI during the colder months. Service stations selling a large volume of fuel will normally have the correct blend to work well at all times throughout the year in their local area. When the weather is very cold, gasoline must be able to vaporize very quickly in order for an engine to start and warm up properly. If summer blend fuel is being used in the winter, little

2.6

AMBIENT AIR TEMP RANGE

FS / FST Service Manual 9921066


Maintenance

CHAPTER 3 Maintenance MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 BREAK-IN PERIOD MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 MAINTENANCE PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

ENGINE OIL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 ENGINE OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 ENGINE OIL AND FILTER CHANGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 AIRBOX OIL BREATHER FOAM ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 SPARK PLUG SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 AIR BOX INTAKE BOOTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 ENGINE LUBRICATION SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8

3

ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 FST AIR FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 ALTERNATOR BELT INSPECTION / ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 VALVE LASH ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9

COOLING SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11 EXPANSION TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11 ENGINE COOLANT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11 ADDING ENGINE COOLANT / AIR BLEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12 COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12 ENGINE COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13 OIL COOLER CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14

PVT / DRIVE SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15 DRIVE BELT DEFLECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15 CHAINCASE CHAIN TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15 TRACK ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16 TRACK TENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17 TRACK LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17

CHASSIS LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 DRIVESHAFT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 CHAINCASE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 CHAINCASE DRAIN PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19 HANDLEBAR ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19 RIDER SELECT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20 THROTTLE LEVER FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20 BRAKE LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20 BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20 BRAKE FLUID BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20

OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21 STORAGE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21

FS / FST Service Manual 9921066

3.1


Maintenance MAINTENANCE Break-In Period Maintenance Interval

500 Mile (800km) Break-In Period Maintenance Table ITEM

The first 500 miles (800 km) of use is considered the break-in period for FS and FST snowmobiles. At the 500 mile (800 km) mark, follow the recommended Break-In Period Maintenance Table.

Air Intake System

Check all air intake hoses and clamps.

FST Reference Hose System

Check the hoses that route between the: -Intake Air Pressure / Temp. Sensorto-Tee Fitting -Tee Fitting-to-Fuel Pressure Regulator -Tee Fitting-to-Purge “Dump” Valve -Wastegate Solenoid-to-Turbo Compressor Housing -Wastegate Solenoid-to-Wastegate Actuator

Chassis / Suspension

Check chassis components for damage, loose fasteners. Check suspension fasteners. Grease rear suspension pivot points / grease zerks.

500 Mile (800km) Break-In Period Maintenance Table ITEM

Field Updates

Engine Oil / Filter

Alternator / Alternator Belt

FST Air Filter

INSTRUCTIONS Reference any and all published Technical Service Bulletins, Team Tips, service literature, or product group literature. Replace the engine oil and filter cartridge. See “Engine Oil and

Filter Change Procedure” on page 3.6. Inspect and check belt tension. Adjust belt if required. See

“Alternator Belt Inspection / Adjustment” on page 3.9. Inspect filter for contamination. Replace as required. (Do not wash filter.) See “FST Air Filter” on

page 3.9.

Airbox Breather Foam

Inspect breather foam and clean if saturated with oil. Always clean after tipping snowmobile3 times on to left side. See “Airbox Oil

Breather Foam Element” on page 3.7.

Cooling System

Verify coolant fluid level in system and recovery bottle. Re-fill as required. Verify cooling system is purged of air. See “Adding

Engine Coolant / Air Bleed” on page 3.12.

Chaincase Drive Chain

Adjust chain deflection. Replace chaincase gear fluid. See

“Chaincase Chain Tension” on page 3.15. Change chaincase oil. See

Chaincase Oil Level

PVT System

3.2

INSTRUCTIONS

“Chaincase Oil Level” on page 3.18. Check, and adjust if required, belt deflection, belt-to-sheave clearance. Inspect belt for abnormal wear.

FS / FST Service Manual 9921066


Maintenance Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and service checks outlined in this manual. All necessary replacement parts and labor incurred, with the exception of authorized warranty repairs, become the responsibility of the registered owner. If, during the course of the warranty period, part failures occur as a result of owner neglect in performing recommended regular maintenance, the cost of repairs are the responsibility of the owner.

Personal safety is critical when attempting to service or adjust your snowmobile. If you're not familiar with safe service or adjustment procedures and the use of tools, or if you don't feel comfortable performing these tasks yourself, contact an authorized Polaris dealer for service. The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Polaris dealer.

Maintenance Intervals z= Perform Service „= Replace Item

Daily / Pre-Ride

Instructions

Yearly or Every mi (km) 1500 (2400)

D

Ignition Start/Stop Switch Test for proper operation. Throttle Safety Switch

D

Safety Slap Switch Lights (Headlights, Taillights, Brake Light) Skags (Wear Bars) Fluid Leaks Parking Brake Brake Lever Coolant

Test for proper operation, replace bulb(s) as needed.

D

Inspect for wear or damage, replace when worn. Inspect for fluid leaks. Test for proper engagement and release. Check lever travel and lever “feel” Inspect level, add as needed.

D D D D D

D

Brake Fluid

Inspect fluid level add as needed.

D

Every 2000(3200km)

Hood Latches Seat latches Rail Slides Foam Oil Breather Element Front/Rear Suspension and Steering Fasteners Front Limiter Strap Oil Lines Alternator Belt Coolant Hoses Heat Exchangers Throttle Lever Fuel Lines Battery Track Alignment Track Tension Handlebars Drive Chain Rear Track Shock (M-10) Gearcase Oil Rear Suspension

Secure properly, replace if damaged. Secure properly, replace if damaged. Inspect for wear or damage, replace when worn. Check pre-ride, clean or replace with each oil change. Clean after tipping 3 times onto left side

D D D

„

D

z

Inspect for missing or loose bolts and fasteners, tighten or replace as needed

Weekly/Before Long Trips

Inspect for wear, damage and missing or loose fasteners, replace as needed Inspect, replace if worn or damaged Check tension and condition, replace if worn or damaged Inspect, replace if worn or damaged Inspect, replace if damaged Inspect, replace if worn or damaged Inspect, replace if worn or damaged Clean terminals, test voltage Verify alignment, adjust as needed Verify tension, adjust as needed Verify alignment, adjust as needed Verify tension, adjust as needed Inspect covers and caps for wear of damage, replace as needed Check at 500 mi (800km), change every 1000 mi (1600km) Lubricate pivot shafts (more often in wet snow conditions)

Weekly/Before Long Trips z z z z z z z z z z z Every 1000(1600) z

3.3 FS / FST Service Manual 9921066

3


Maintenance Maintenance Intervals z= Perform Service „= Replace Item Bearings Throttle Cable

Instructions

Hoses Brake Pads/Disc Fuel Vent Lines Ski Toe Cooling Fins/Shroud

Lubricate drive shaft and jackshaft bearings. Lubricate Verify offset alignment, inspect for wear, residue, loose bushings, see your dealer for all service. Check tension and condition, replace if worn or damaged. Inspect for oil and dirt, replace as needed. Replace oil and filter. Inspect, replace if worn or damaged. Inspect condition, replace as needed. Check muffler and pipe condition, replace damaged or missing components, clean plastic surfaces. Inspect for wear, damage and proper routing replace as needed. Inspect, replace if worn or damaged. Inspect, replace if worn or damaged. Verify alignment. Inspect and clean.

Valve Lash

Adjust as needed.

Cooling System

Bleed the cooling system, inspect for leaks and proper circulation.

Fuel Filter

Inspect, replace as needed.

Suspension Shock Oil

Inspect, replace or rebuild as needed or every 2000 miles (3200km).

Clutches Drive Belt FST Air Filter Oil/Filter Change Engine Mounts Spark Plugs Exhaust System

3.4

FS / FST Service Manual 9921066

Daily / Pre-Ride

Yearly or Every mi (km) 1500 (2400) z z z z z „ z z z z z z z z Initially: 1,500 (2400) After initial service: 10,000 (16,000) Every 2000 (3200) Every 2000 (3200) Every 2000 (3200)


Maintenance ENGINE OIL MAINTENANCE Engine Oil Level Check NOTE: The following procedure must be performed when the engine coolant temperature is between 145° and 160° F (63° - 71°C). Failure to verify engine oil level between these temperatures will yield false oil level readings.

NOTE: The oil level inside the storage tank will only be accurate for approximately 3 minutes after stopping the engine. After 3 minutes, re-start the engine and let idle for 20 seconds to re-fill the storage tank. 8.

Maintain the oil level just above the “LOWER OPERATING LEVEL” mark. If the level is low, add oil in 2 oz. increments and re-check the level. MAINTAIN OIL LEVEL HERE

CAUTION

3

Severe engine damage may occur if the procedure for checking the oil level is not followed precisely. Always verify the oil level with the snowmobile on a flat, level surface. Always check the oil level when the engine coolant temperature is within the specified range.

WARNING Never attempt to verify the oil level inside the storage tank immediately after operating the snowmobile at a high rate of speed for an extended period of time OR if the nose of the snowmobile is pointed downwards.

9.

If the oil level is high. the excess oil MUST be removed from the storage tank. Again, remove excess oil from the tank in 2 oz. increments.

CAUTION Never overfill the oil storage tank. Severe engine damage, airbox / EMS sensor damage, or poor engine performance may occur if the storage tank is overfilled.

Always close the engine compartment doors and hood while the engine is running. Always run the engine outside or in an open environment with plenty of fresh air. 1.

2. 3.

4.

5. 6. 7.

To verify there is oil in the storage tank, position the snowmobile on a flat, level surface. Start the engine and let run for no more than 5 seconds. Turn off the engine. Verify there is engine oil on the dipstick. If low, add just enough oil so that oil can be seen on the dipstick. If the engine is cold (engine temperature is not between 145° and 160°F), start the engine and allow it to idle until the engine coolant temperature reaches the specified range. Proceed with step 4. If the engine has been running, stop the engine and verify the engine coolant temperature is within the specified range. Allow the engine to cool if required. Once the coolant temperature is within the specified range, re-start the engine and let it run for no more than 20 seconds to circulate the oil from the engine back into the storage tank. Turn the engine off. Remove and clean the dipstick. Re-insert the dipstick completely. Quickly remove dipstick again to verify the oil level.

3.5 FS / FST Service Manual 9921066


Maintenance Engine Oil and Filter Change Procedure 14.

WARNING The following procedure involves working with and around hot oil, engine parts, and exhaust components which can cause serious burns if your skin or clothing comes into contact with them. Never turnover the engine or run the engine without first closing the side panels and hood on the snowmobile. Always run the engine outside or in an open environment with plenty of fresh air. NOTE: A jumper harness, PN 4011491, is required to bypass the main relay system so the engine can be turned-over using the start key without starting the engine. The jumper is included with the oil change kit, PN 2875522. The kit includes the jumper, three quarts of Polaris 0W-50 synthetic oil, one oil filter cartridge, and o ring.

15. 16. 17.

18. 19. 20. 21. 22. 23. 24.

25.

JUMPER HARNESS (4011491)

1. 2.

Position the snowmobile on a flat, level surface. Verify the engine coolant temperature is between 145° and 160°F (63° - 71°C). NOTE: The coolant temperature must be within the specified range prior to beginning the oil change procedure. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Verify the engine is off. Open the hood, and remove the left-side panel. Disconnect the starter motor solenoid control harness. Insert the female WHT/RED plug into the male pin from the solenoid. Insert the BROWN male pin from the jumper harness into the solenoid’s female port. Open the handlebar cover. Locate the connector with the BROWN and RED/WHITE wires connected to it. Connect the plug from the jumper to the handlebar harness connector so that the BROWN wires match. Open the fuse panel cover and remove the 20A EFI fuse from the fuse panel. Reinstall the left-side compartment door panel. Remove the oil return hose from the front of the oil storage tank. Have an assistant, wearing eye protection and protective

3.6

26. 27. 28. 29. 30.

31.

32. 33.

gloves, position the end of the hose into an oil collection container or oil pan. Turn the start key to the “START” position and hold until the ECU switches the solenoid off. Wait 30 seconds to allow the starter motor to cool down. Repeat steps 14 and 15 four more times for a total of five cycles. Reinstall the oil return hose and tighten the gear clamp. Verify the hose cannot be pulled off of the storage tank’s nozzle, but do not overtighten the clamp. Remove the jumper harness from the handlebar harness and starter solenoid plug. Reconnect the starter solenoid plug to the solenoid. Reinstall the 20A EFI fuse, then install the cover. REMOVE THE KEY FROM THE IGNITION SWITCH. Open the air box by removing the top cover plate. Locate the foam breather in the back of the airbox. Clean the foam breather using a mixture of hot, soapy water and allow to air dry. Locate the oil filter cover. Verify at least five minutes has passed since the engine has been turned over before removing filter cover. Remove filter cover. Remove filter from inside of cover and inspect for signs of foreign material such as metal pieces. Insert new filter element into cover. Inspect oil filter cap o-ring. Replace o-ring if damaged. Reinstall o-ring and torque cover to 17 ft.lbs. (23Nm). Re-install the foam breather element (if dry) into the air box and secure air box cover. Remove the oil storage tank dipstick and add two quarts of Polaris 0W-50 synthetic oil to the tank. Reinstall the dipstick. Start the engine and run until the engine coolant temperature is between 145° and 160°F. Turn off the engine. Remove the dipstick and clean with a shop rag. Reinstall the dipstick and screw in completely. Remove the dipstick and observe the oil level. Add oil to bring the oil level up to just above the “LOWER OPERATING LEVEL” mark. DO NOT OVERFILL THE OIL STORAGE TANK. MAINTAIN OIL LEVEL HERE

34. Reinstall the dipstick and test drive the snowmobile.

FS / FST Service Manual 9921066


Maintenance Airbox Oil Breather Foam Element

3.

The breather foam will soak up oil discharged by the ventilation cyclone.

4.

Clean the element in a mixture of hot water and dishwater soap. Once clean, air dry the element. Reinstall the element when dry. Reinstall the airbox cover and fasten each retaining clip.

Spark Plug Servicing Due to the location of several components, follow these steps to access the MAG-side ignition coil pack. 1. 2. 3. 4. 5. 6.

Remove the screw securing the filler neck to the oil storage tank. Re-route the bleed hose so it is not between the fuel hoses. Move the filler neck away from storage tank, then move bleed hose out of the way of the coil. Lift the cooling hose to access the ignition coil pack. Torque spark plug to 18 - 20 Ft.Lbs. (24 - 27 Nm). Torque the coil pack fasteners to 7 Ft.Lbs. (10 Nm). Return bleed hose to original position. Do not over-tighten the filler neck-to-storage tank fastener.

Air Box Intake Boots The rubber intake boots on all FS air boxes are sealed to the air box using Loctite 401 glue. If the boots become loose, they can be re-glued using Loctite 401 or an everyday, high strength super glue. Before the glue application, thoroughly clean the mating surfaces and remove any loose material. Spread the glue evenly across the mating surfaces, then press the boot(s) on to the air box. Follow the manufacture’s curing time instructions. Additionally, always verify the foam block is adhered to the back of the FS airbox. If the foam block is missing, the airbox will shift during vehicle operation. Clean the element during each oil change and after the snowmobile has been tipped over on to its left-side three or more times.

On all FST snowmobiles, the rubber intake boots are secured to the boost box using Loctite 380 Black Max and a set of gear clamps.

CAUTION

Again, similar to repairing an FS airbox, all mating surfaces should be clean and free from adhesive flakes. Evenly spread a new film of Loctite 380 Black Max to the boot and airbox mating surfaces.

Operating the snowmobile with a saturated breather element may cause severe engine damage and/or poor engine performance. Tipping the snowmobile over on to its left side or rolling the snowmobile over increases the amount of oil discharged by the ventilation system. 1. 2.

Secure both rubber boots with gear clamps within 10 minutes of glue application. Tighten gear clamps to 1.5 ft.lbs. While the airbox can be installed in the engine compartment, always allow the adhesive to cure for at least 24 hours before starting the engine.

Open the hood, then open the air box cover. Remove the breather foam and inspect for damage. Replace the element if damaged.

3.7 FS / FST Service Manual 9921066

3


Maintenance Engine Lubrication System Overview

pump, oil filter, main - counter balancer - piston jets, cylinder head oil supply and turbocharger oil supply on FST models.

There are two lubrication systems; low and high pressure. The low pressure lubrication system consists of the engine sump scavenge pump, oil cooler, and storage tank. The high pressure lubrication system consists of the storage tank, high pressure oil

3.8

A crankcase ventilation system is used to return unburned fuel vapors present in the oil storage tank to the air intake system as well as oil mist back into the engine sump.

FS / FST Service Manual 9921066


Maintenance ENGINE MAINTENANCE

Valve Lash Adjustment

FST Air Filter

1. 2. 3.

FST models feature an air filter element to protect the turbocharger compressor. Replace the air filter if damaged, dirty or saturated with engine oil.

4. 5. 6. 7.

8. 9. 10.

11. 12. 13.

NOTE: Do not clean the air filter cartridge.

Alternator Belt Inspection / Adjustment The alternator belt deflection must be maintained to ensure trouble-free operation. 1.

Inspect the alternator belt deflection by rotating the belt as far as possible. The correct amount of deflection is achieved when the belt can only be twisted 90 degrees from its operating postion.

14.

15. 16.

Open the hood and remove the left-side door panel. Remove the key from the ignition switch. Remove the airbox / clutch guard from the engine compartment. Remove the console assembly. Remove the seat assembly to gain access to the fuel tank. Remove the fasteners securing the fuel tank to the tunnel. Cover the supply and return fuel hose connectors with a clean shop rag. Disconnect the fuel hoses from the fuel pump flange. Disconnect the fuel pump wiring harness. Remove the fuel tank from the snowmobile. Remove the wiring harness connectors from the ignition coils and cam phase sensor. Verify each connector is labeled with its position. Label connector for re-assembly if required. Remove the air intake tube (FST models) that is routed over the top of the valve cover. Remove the ignition coils, then remove the valve cover. Rotate the drive clutch in the direction of forward vehicle operation until the rocker arms on the PTO-side of the engine are at TDC-compression stroke. The TDCcompression stroke can be identified when the rockers arms are loose and not contacting the camshaft lobes. Insert a feeler gauge between the valve shim and rocker arm tappet at each valve location. Write-down each measurement. Compare each measurement to the specification. If the valve shim clearance is within specification, no change is required. If the clearance is outside the specification, the valve shim must be replaced with one that will satisfy the specification.

Valve Clearance ENGINE / VALVES 2. 3. 4. 5.

Adjust the belt deflection by loosening the upper and lower alternator fasteners. Insert a large pry bar between the crankcase and alternator and pull firmly. Twist the belt while pulling back on the pry bar. Have an assistant tighten the two alternator fasteners once the correct belt deflection is achieved.

SPECIFICATION

NA Intake Exhaust

.08 -.15mm (.003″ -.006″) .15 -.22mm (.006″ -.008″)

Turbo Intake Exhaust

.08 -.15mm (.003″ -.006″) .18 -.25mm (.007″ -.009″)

3.9 FS / FST Service Manual 9921066

3


Maintenance 17. To remove each valve shim, install the valve shim guillotine tool, PN: PW-47163, on to the cylinder head.

20. Extract each shim with a pick, or remove the rocker arm axle, then rocker arm, and then the shim.

CAUTION DO NOT DROP SHIMS INTO ENGINE.

18. Insert the open-end of a 18mm wrench around one of the rocker arms. Gently compress the rocker arm and push the valves downwards.

21. Measure the thickness of each shim removed from the engine and note next to the corresponding valve clearance measured in previous steps.

22. Select a new valve shim, thicker or thinner, from the table that will bring the measured valve clearance back into specification. NOTE: Do not compress the valves into the piston face. Do not dis-lodge the valve stem keys. 19. Engage the guillotines over the valve assemblies. Remove the wrench.

3.10

FS / FST Service Manual 9921066


Maintenance COOLING SYSTEM MAINTENANCE

Valve Shims SHIM THICKNESS (MM)

PART NUMBER

2.50

0452014

2.55

0452015

2.60

0452016

2.65

0452017

2.70

0452018

2.75

0452019

2.80

0452020

2.85

0452021

2.90

0452022

2.95

0452000

3.00

0452001

3.05

0452023

3.10

0452002

3.15

0452003

3.20

0452004

3.25

0452005

3.30

0452024

3.35

0452006

3.40

0452007

3.45

0452008

3.50

0452009

3.55

0452010

3.60

0452011

3.65

0452012

1.

3.70

0452013

2.

Expansion Tank When the engine is cold, the coolant level should be at the COLD FILL LINE. Only add or remove coolant from the system when the engine is cold. NOTE: Do not overfill the expansion tank. Coolant inside the tank will rise as engine temperature increases.

Engine Coolant Removal

23. After completing the valve lash adjustment on the PTO cylinder valve train, remove the valve lash adjustment tool from the cylinder head. 24. Rotate the drive clutch in the direction of normal rotation until the MAG piston is at TDC-compression stroke. 25. Perform the valve adjustment procedure on the MAG cylinder valve train. 26. When completed, re-install the valve cover. Verify the rocker arm retaining tabs inside the valve cover are seated. Tighten the valve cover fasteners to 7 ft.lbs. (10 Nm). 27. Re-install the ignition coils and torque fasteners to 7 ft.lbs. (10 Nm).

To drain the cooling system, place towels or floor dry underneath the snowmobile. Using a siphon, remove as much coolant as possible from the filler cap location.

3.11 FS / FST Service Manual 9921066

3


Maintenance 3.

head. Place a towel or shop rag underneath the screw.

Remove the hose connecting the main tee to the radiator. Pour as much coolant out as possible into a container.

7. 4.

Insert the siphon into the tee fitting and into the hose connected to the water pump. Remove the rest of the coolant.

8. 9. 10. 11. 12. 13. 14. 15. 16.

Open the screw just enough to allow air and coolant to escape. Start the engine. Run the engine until the temperature displayed on the gauge is at or above 180°F (82°C). Continue running the engine. Monitor the air bleed screw. Close the screw when a steady stream of coolant flows out of the hole. Verify the heat exchanges are warm to the touch. Turn off the engine. Top-off the main fill tube, then replace the cap. Allow the engine to cool completely. Reinstall the clutch guard / air intake. Add coolant to the expansion tank to bring the fluid level up to the COLD FILL LINE.

Cooling System Pressure Test To test the pressure-holding capability and to check for system leaks, perform a pressure test.

Adding Engine Coolant / Air Bleed NOTE: When adding coolant after the engine has been drained or when pockets of air within the system are suspected, the air must be removed to prevent serious engine damage. 1. 2. 3. 4. 5. 6.

Verify all of the cooling hoses are secured to each fitting with a clamp. Fill the system at the main filler neck with a 60%Proplyne Glycol / 40% distilled water mixture, Polaris PN 2871323. Add coolant to bring the level up to the fill tube opening. Remove the clutch guard / air intake assembly and set aside. Close the engine compartment door. Safely raise the front of the snowmobile using a floor jack or snowmobile lift until the skis are off the ground. Locate the air bleed screw on the PTO-side of the cylinder

3.12

1. 2. 3. 4. 5.

Remove the filler neck-to-expansion tank hose from the filler neck (top hose). Connect a Mity Vac hand pump to the filler neck nozzle. Pressurize the cooling system to 14 psi (1 bar). The cooling system should hold the pressure for at least 5 minutes. During the test, look and listen for leaks.

FS / FST Service Manual 9921066

Connect Mity Vac to top nozzle.


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2006 POLARIS FST SWITCHBACK SNOWMOBILE Service Repair Manual  
2006 POLARIS FST SWITCHBACK SNOWMOBILE Service Repair Manual  
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